M A R C H 2 0 18

PUMPSANDSYSTEMS.COM

SYSTEMS
The Leading Magazine for Pump Users Worldwide

TRITON: FIGHTING THIS

CYBERSECURITY THREAT

SHREDDER PUMPS
TAKE ON PRISON
CONTRABAND

BEYOND THE
STANDARD
STUFFING BOX

& U P G R A D E S
R E ST O R A T I O N b R ul e C
o m p li a n ce | U
n co m m o
n S h af t B r e ak s

6
e r a t e | EPA 31
H ydr a ul i c R
Engineering Pumps
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2 FROM THE EDITOR

A s you may have noticed,

this year we have been
reflecting back on 25 years of
EDITORIAL
SENIOR EDITOR, PUMPS DIVISION: Alecia Archibald
aarchibald@cahabamedia.com • 205-278-2843
Pumps & Systems magazine by MANAGING EDITOR: Savanna Gray
sgray@cahabamedia.com • 205-278-2839
reintroducing some classics from
MANAGING EDITOR: Drew Champlin
1993. We are especially proud dchamplin@cahabamedia.com • 205-314-8264
this issue because we were able CONTRIBUTING EDITORS: Lev Nelik,
to feature the same author from Ray Hardee, Jim Elsey
then and now. Both articles relate
to the aftermarket. CREATIVE SERVICES
Kurt Schumann, now the DIGITAL PROJECT MANAGER &
Drew Champlin of P&S and Pulsafeeder’s Axel Bokiba visit SENIOR ART DIRECTOR: Greg Ragsdale
president of ProPump Services at December’s Turbomachinery & Pump Symposium. ART DIRECTOR: Elizabeth Chick
LLC, wrote for us in our first year WEB DEVELOPER: Greg Caudle
of publication when he penned a piece on upgrading utility and process pumps. At the DIGITAL COMMUNITY MANAGER: Amy Cash
time, Schumann worked for Ingersoll-Dresser Pump Company. Following that piece
(page 46) is a present-day article from Schumann on updating circulating water systems CIRCULATION
to comply with EPA 316b. We appreciate his contributions over the last 25 years and are AUDIENCE DEVELOPMENT MANAGER: Lori Masaoay
lmasaoay@cahabamedia.com • 205-278-2840
happy to publish both articles in this aftermarket issue.
Our cover series begins on page 37 with an interesting piece on how a pump’s ADVERTISING
hydraulic rerate restored a reactor charge pump of a major oil refinery. We also have NATIONAL SALES MANAGER:
coverage on chopper and shredder pumps and how their versatile uses have solved Derrell Moody
many problems in various applications. dmoody@pump-zone.com • 205-345-0784
We are making an effort to cover couplings more frequently this year. Check out page SENIOR ACCOUNT EXECUTIVES:
58 for a wonderful infographic on the STAMP acronym on how to choose the proper Mary-Kathryn Baker
coupling for your pump. Do you have other couplings topics you would like to see us mkbaker@pump-zone.com • 205-345-6036
write about? Or contribute? Email me at dchamplin@cahabamedia.com. Mark Goins
mgoins@pump-zone.com • 205-345-6414
We would also like to welcome Axel Bokiba, Pulsafeeder’s vice president of product
Garrick Stone
management, to our Editorial Advisory Board. gstone@pump-zone.com • 205-212-9406
I had a chance to meet Bokiba at Turbomachinery & Pump Symposium in Houston CLIENT SERVICES COORDINATOR:
last December (pictured). Bokiba has spent the last 10 years in the pump industry Krystal Parker
helping to develop technology for offshore oil and gas flow assurance and shale kparker@pump-zone.com • 205-561-2600
operations that need chemical injection. He is an expert in the use of metering for gear
pumps for industrial water and wastewater treatment applications.
Bokiba has been a key contributor to our magazine and has presented webinars on
pumpsandsystems.com.
As always, thanks for reading! PUBLISHER: Walter B. Evans Jr.
VP OF SALES: Greg Meineke
CREATIVE DIRECTOR: Terri J. Gray
CONTROLLER: Brandon Whittemore

P.O. Box 530067

Birmingham, AL 35253
Managing Editor, Drew Champlin EDITORIAL & PRODUCTION
dchamplin@cahabamedia.com 1900 28th Avenue South, Suite 200
Birmingham, AL 35209
205-212-9402
ADVERTISING SALES
Pumps & Systems 1806 6th Street, Suite 200
is a member of the following organizations: Tuscaloosa, AL 35401
PUMPS & SYSTEMS (ISSN# 1065-108X) is published monthly by Cahaba Media Group, 1900 28th Avenue So., Suite 200, Birmingham, AL 35209. Periodicals
205-345-0784
postage paid at Birmingham, AL, and additional mailing offices. Subscriptions: Free of charge to qualified industrial pump users. Publisher reserves the
right to determine qualifications. Annual subscriptions: US and possessions $48, all other countries $125 US funds (via air mail). Single copies: US and
possessions $5, all other countries $15 US funds (via air mail). Call 205-278-2840 inside or outside the U.S. POSTMASTER: Send changes of address and
form 3579 to Pumps & Systems, P.O. Box 530067, Birmingham, AL 35253. ©2018 Cahaba Media Group, Inc. No part of this publication may be reproduced
without the written consent of the publisher. The publisher does not warrant, either expressly or by implication, the factual accuracy of any advertise-
ments, articles or descriptions herein, nor does the publisher warrant the validity of any views or opinions offered by the authors of said articles or descrip-
tions. The opinions expressed are those of the individual authors, and do not necessarily represent the opinions of Cahaba Media Group. Cahaba Media
Group makes no representation or warranties regarding the accuracy or appropriateness of the advice or any advertisements contained in this magazine.
SUBMISSIONS: We welcome submissions. Unless otherwise negotiated in writing by the editors, by sending us your submission, you grant Cahaba Media
Group, Inc., permission by an irrevocable license (with the right to license to third parties) to edit, reproduce, distribute, publish and adapt your submission
in any medium on multiple occasions. You are free to publish your submission yourself or to allow others to republish your submission. Submissions will
not be returned. Volume 26, Issue 3.

March 2 0 1 8 | Pum ps & S y st e m s

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4
This issue MARCH
Volume 26 • Number 3

COVER COLUMNS
SERIES AFTERMARKET
PUMPING PRESCRIPTIONS
16 By Lev Nelik, Ph.D., P.E.
Pumping Machinery LLC
Middle East: What’s New with
Pumping Challenges in Israel?
PUMP SYSTEM IMPROVEMENT
18 By Dominik Fry, P.E
Engineered Software Inc.
Proper Pump Selection: Avoid

37 Oversizing Your Pumps

COMMON PUMPING MISTAKES

37 ENGINEERING ANALYSIS OF A REACTOR CHARGE PUMP 24 By Jim Elsey
LEADS TO FULL RESTORATION Summit Pump Inc.
By Gary Dyson, Hydro, Inc. A Centrifugal Pump Primer, Part 2
Thomas Hess, Monroe Energy
A detailed study and hydraulic rerate improves operating conditions for an
ultra-low sulfur gasoline reactor charge pump.

46 PUMPS & SYSTEMS LOOKS BACK: 2 FROM THE EDITOR

UPGRADING UTILITY & PROCESS PUMPS
By Kurt Schumann 8 NEWS
Improvements to make your equipment better than new.
14 FROM THE READERS
48 HOW TO UPDATE CIRCULATING
WATER SYSTEMS TO COMPLY
WITH EPA 316B 53 75 PRODUCTS

By Kurt Schumann, 77 ADVERTISERS INDEX

ProPump Services LLC
A site visit and testing are critical to 77 PUMP USERS MARKETPLACE
the process.
80 PUMP MARKET ANALYSIS
53 WHAT CAUSES SHAFT BREAKS
IN POSITIVE DISPLACEMENT
GEAR PUMPS?
By Stephen Bell, Carotek
This plant solved the mystery of
sudden, frequent pump failures.

58 COUPLINGS 59 THE RISE OF ICS MALWARE 61 DEBUNKING THE

By Brent Harrison, By Barak Perelman, MILLENNIAL MYTH
SSPECIAL
PECIAL MAX Industrial Solutions Indegy By Andrew Yeghnazar,
REPORT BLACOH Industries
How to Choose the Proper What can these programs
Coupling for Your Pump do, and what are the Understand younger employees,
capabilities you need to and learn how to make the
protect your system? workplace work with them.

March 2 0 1 8 | Pum ps & S y st e m s

UNMATCHED RELIABILITY.
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See why the original chopper pump is still unmatched.
• Expedite pumps and parts delivery
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• Hardened wear components
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• 6 individual chopping features
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• Free trial program available
• Ask about our on-site chopper pump demonstration
Experience ease of maintenance with Vaughan Chopper Pumps.

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Contact Vaughan for our extensive list of references.

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6
This issue DEPARTMENTS
MARCH
CHOPPER & SHREDDER PUMPS
SSPECIAL
PECIAL 64 MAINTENANCE MINDERS
SECTION Maintenance Strategies for
Efficient Installed Assets
26 SHREDDER PUMPS SOLVE CONTRABAND-CREATED PROBLEM IN By Frederic Baudart, CMRP,
CORRECTIONAL FACILITY Fluke Accelix
By Keith Grgurich & Gary Brown, BJM Pumps
Foreign materials in sewage system led the maintenance team to look for a new
equipment option. 68 SEALING SENSE
Compression Packing:
A Look Beyond the Standard
28 CHOPPERS FIND CREATIVE USE AS CONDITIONING PUMP Stuffing Box
By Derek Vaughan, Vaughan Company
By Mark Freeman,
A different element contributed to the de-clogging of a wet well. FSA Member,
EGC Engineered Solutions
29 REVERSING GRINDER PUMPS
PREVENT CLOGGING
73 HI PUMP FAQS
ON RANDALL’S ISLAND Finding System
By Stephen Doolittle, Inefficiencies & Positive
Zoeller Engineered Products Displacement Pump Basics
A retrofit brought reliability to the By Hydraulic Institute
island’s wastewater system.

32 MANHOLE SYSTEM REPLACES

FAILING GRINDERS IN TRAVEL
CENTER CHAIN FACILITY
By Kailey Habermann,
JWC Environmental M A R C H 2 0 18
PUMPSANDSYSTEMS.COM

SYSTEMS
With frequent clogging problems, the The Leading Magazine for Pump Users Worldwide

ON THE COVER
company was paying around $100,000 Photo courtesy of
per year in unscheduled maintenance. Hydro, Inc.

32
TRITON: FIGHTING THIS
CYBERSECURITY THREAT

SHREDDER PUMPS
TAKE ON PRISON
CONTRABAND

BEYOND THE
STANDARD
STUFFING BOX

& UPGRADES
RESTORATION
s
Shaft Break
Uncommon
liance |
Rule Comp
| EPA 316b
Rerate
Hydraulic

EDITORIAL ADVISORY BOARD

THOMAS L. ANGLE, P.E., MSC,
Geschaeftsleiter (CEO), Swiss Flow
Solutions GmbH
BRYAN S. BARRINGTON, Machinery
Engineer, Lyondell Chemical Co.
RUSSELL SMITH, Business Dev.
Manager - Wastewater, Grundfos
Americas Corporation
AXEL BOKIBA, Vice President of
Project Management, Pulsafeeder
R. THOMAS BROWN III, President,
Advanced Sealing International (ASI)
CHRIS CALDWELL, Director of
Advanced Collection Technology,
Business Area Wastewater Solutions,
Sulzer Pumps, ABS USA
JACK CREAMER, Market Segment
Manager – Pumping Equipment,
Square D by Schneider Electric
BOB DOMKOWSKI, Business
Development Manager – Transport
Pumping and Amusement Markets/
Engineering Consultant, Xylem, Inc.,
Water Solutions USA – Flygt
WALT ERNDT, VP/GM, CRANE Pumps
& Systems
JOE EVANS, Ph.D., Customer &
Employee Education, PumpTech, Inc.
LARRY LEWIS, President, Vanton
Pump and Equipment Corp.
WILLIAM LIVOTI, Business
Development Manager/Energy
Efficiency Specialist, WEG Electric
Corporation
TODD LOUDIN, President/CEO North
American Operations, Flowrox Inc.
MICHAEL MICHAUD, Executive
Director, Hydraulic Institute
JOHN MALINOWSKI, Industrial Motor
Consultant
WILLIAM E. NEIS, P.E., President,
Northeast Industrial Sales
LEV NELIK, Ph.D., P.E., APICS,
International Center for Pumps
Research and Development, Israel
HENRY PECK, President, Geiger Pump
& Equipment Company
MARIANNE SZCZECH, Director,
Global Marketing and Product
Management, Pump Solutions Group
SCOTT SORENSEN, Oil & Gas
Automation Consultant & Market
Developer, Siemens Industry Sector
ADAM STOLBERG, Executive Director,
Submersible Wastewater Pump
Association (SWPA)
JERRY TURNER, Founder/Senior
Advisor, Pioneer Pump
DOUG VOLDEN, Global Engineering
Director, John Crane
KIRK WILSON, President, Services &
Solutions, Flowserve Corporation
JAMES WONG, Associate Product
Manager – Bearing Isolator, Garlock
Sealing Technologies

March 2 0 1 8 | Pum ps & S y st e m s

 Complete visibility means
higher productivity.

Flowserve IoT solutions offer both

advanced monitoring technology
and robust model-based analytics
to provide you with better visibility
into the performance of your plant’s
equipment.
Detect, diagnose and resolve
potential problems faster.

Visit www.flowserve.com/IoT for an overview

of IoT and reliability solutions from Flowserve.

© 2018 Flowserve Corporation

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8 NEWS
NEW HIRES,
PROMOTIONS & RECOGNITIONS
DR. FALK SCHAFER, KSB
RICHMOND, Va. – Dr. Falk Schäfer began his new
role in the U.S. as managing director of KSB, Inc. on
March 1. Schafer began his career with KSB in 1994
as an industrial mechanic in Frankenthal, Germany.
He received his mechanical engineering degree at
the University of Applied Sciences in Kaiserslautern,
Germany, and then went on to achieve his PhD in Dr. Falk
optimization of vertical pumping systems in 2008. Schäfer
Schäfer has held various positions at KSB, from project manager—
energy efficiency of pumping systems, head of system efficiency
services department, vice president of engineering services, and
director of pump services in Germany. ksb.com
BRENT VYVIAL,
STRESS ENGINEERING SERVICES
HOUSTON – Stress Engineering Services, Inc., (SES)
has appointed Brent Vyvial as principal and lead of
its midstream practice. Based in Houston, Vyvial
will oversee the midstream group, manage project
and personnel activity and coordinate business
development within the practice. Brent
Vyvial joined SES in 2006 as an analyst and is Vyvial
currently a principal in the company.
His research activities at Stress have included studies associated
with design of subsea flowlines and silicon-controlled rectifiers (SCR)
using the strain-based rules of API RP 1111, investigations of composite
pipeline repair systems at elevated temperatures conducted for
manufacturers and pipeline operators and numerous full-scale test
programs to evaluate pipeline anomalies.
Vyvial holds a Master of Science degree in mechanical engineering
from Texas A&M University. stress.com
STEVE PAULSEN, PG FLOW SOLUTIONS
HVALSTAD, Norway – Liquid handling and pump specialist PG Flow
Solutions has promoted chief operating officer Steve Paulsen to the role
of chief executive officer.
Paulsen succeeds Roy Norum, who moves into the role as executive
vice president for sales and business development, overseeing the
group’s sales, marketing and business development activities globally.
The change is part of a long-term succession plan which was mapped
out in 2014, when Norvestor VI, L.P., a fund advised by Norvestor Equity
AS, became the majority owner of PG Flow Solutions. The search for PG’s
next generation top executive started immediately, and in 2015 Paulsen
joined the company as its first COO.
Prior to joining PG Flow Solutions in 2015, Paulsen spent almost a
decade with Siemens as head of operations within energy, oil and gas
solutions, head of global sales and project execution, and head of sales
and regional support.
He has also spent several years in project director roles for Nokia
Siemens Networks. pg-flowsolutions.com
March 2 0 1 8 | Pu m ps & S y st e m s
BRIAN WRIGHT, ERIC KEARBEY,
WILLIE HODESS, BOB BRIENO, SEEPEX
ENON, Ohio – SEEPEX Inc. announced new sales personnel hired in the
fourth quarter of 2017. Brian Wright is the new business development
sales manager for Texas. Wright’s extensive experience in the pump
industry, particularly oil and gas markets, will be helpful in his new role
at SEEPEX.
Eric Kearbey is the new territory sales manager for the Midwest.
Kearbey will cover Illinois, Missouri, Kansas and Oklahoma. He has a
Bachelor of Science degree in chemical engineering from the
University of Missouri and has more than 20 years of experience in the
pump industry.
Willie Hodess is the new territory sales manager for Manitoba and
Ontario, Canada. Hodess has 20 years of experience in the pump
industry, managing distribution and selling engineered products within
a variety of markets.
Bob Brieno is the new territory sales manager for the West Coast
which includes California, Oregon, Washington, Hawaii, Alaska and a
portion of Nevada. Brieno has several years of experience in the pump
industry, and a commendable military background of more than 20
years. seepex.com
ED MOHRBACH, WALL COLMONOY
MADISON HEIGHTS, Mich. – Wall Colmonoy
named Ed Mohrbach vice president of finance
and operations. Mohrbach joined Wall Colmonoy
in January 2017, bringing with him extensive
experience in the industrial segment with
leadership roles in sales and marketing and general
management. In the last 13 years, Mohrbach was Ed
president of the PCS Company, a manufacturer and Mohrbach
distributor of products within the plastics industry.
At Wall Colmonoy, Mohrbach will work closely with management of
all domestic divisions—alloy products, aerobraze and Franklin Bronze
Precision Components, LLC., to drive profitable sales growth through
the ongoing development and refinement of their respective business
strategies and tactical programs. wallcolmonoy.com
ROBERT MARSIGLIA, ASAHI/AMERICA
LAWRENCE, Mass. – Asahi/America, Inc., announced the addition of
Robert Marsiglia to its business development team. Marsiglia joined
Asahi/America on February 1 as business development and national
sales manager for commercial products.
Marsiglia brings 30 years of direct sales, distribution and rep
management with him to Asahi/America, where he will work closely
with the company’s sales team on sales efforts and engineering
specifications. Marsiglia’s background also includes experience in
industrial process and high purity product development, and process
piping systems and equipment. Additionally, Marsiglia holds degrees
in mechanical technology and mechanical engineering, and he was
previously a certified plumbing engineer. asahi-america.com
 9

Is Now
ISO 9001:2015
Certified
PETER CLARKE, EXXONMOBIL
IRVING, Texas – The board of directors of
Exxon Mobil Corporation appointed Peter
PRECISION CHEMICAL METERING
Clarke as president of ExxonMobil Gas & Power QUALITY & PERFORMANCE
Marketing Company and elected him as a vice

Flex-Pro A2
president of the corporation. Clarke is currently PROVEN
vice president, international gas, ExxonMobil ® PERFORMANCE
Gas & Power Marketing Company, and lead IN THE TOUGHEST
country manager for ExxonMobil businesses in APPLICATIONS
the U.K. Flex-Pro® Peristaltic
This comes following the retirement of Rob Metering Pumps can
Franklin, president of ExxonMobil Gas & Power handle the often
Marketing Company, effective March 1, 2018, aggressive and high
after more than 35 years of service. viscosity fluids used for
the treatment of both
Franklin, 60, was appointed president, Water and Waste Water,
ExxonMobil Gas & Power Marketing Company including Peracetic Acid.
effective March 1, 2013, and elected as a vice A wide range of feed
president of the corporation, effective May 1, capabilities and materials
2009. exxonmobil.com options are available.
• One button Prime.
KIM JENSEN, GRUNDFOS • Multiple Signal Input &
Output (4-20Ma, etc.)
SINGAPORE – Grundfos announced the
• Two CNC precision
appointment of Kim Jensen to the role of group machined squeeze
senior vice president and regional managing rollers and two
director of Grundfos Asia Pacific region. alignment rollers
In his new role, Jensen will lead the provide optimum
squeeze for
company’s business across 22 countries unparalleled accuracy.
including 13 wholly-owned sales companies IP66 • Built-in Patented Tube
and local assembly plants Grundfos operates in Failure Detection.
the region.
NEMA 4X
WASH DOWN • Exclusive Multi-Tube
He will also spearhead opportunities for technology gives
the company’s development and expansion in extended tube life.
Asia Pacific.
Prior to his Asia Pacific role, Jensen was
Group Senior Vice President and Regional
Managing Director for the Europe, Middle East
and Africa (EMEA) markets since 2015, where PUMP FOR • Gentle pumping
action for long
he oversaw 2,800 employees in areas of sales,
marketing and customer service. POLYMER chain polymers.
• TFD+: detects
Jensen has been with Grundfos for more
than 25 years, working across Europe and the
FEED oil and water
based polymer
spills in the pump
Middle East. He succeeds Okay Barutçu, who head and alerts
held the role since 2014 and will be moving operator to leaks.
to Dubai to take the role of Senior Vice • Equipped
President and Regional Managing Director of with long-
Grundfos East Europe, Western Asia and Africa lived polymer
compatible
(EEWAA) markets. tubing.
EEWAA is a newly defined sales region • Ideal for low and
together with Western Europe (WEREG), which
Circle 118 on card or visit psfreeinfo.com.

high viscosity
made up the original EMEA markets before fluids.
the split effective January 1, 2018, to support • Feed control
Grundfos’ global growth ambition. adjustment and
feed rate options
grundfos.com are offered.
• Self priming.

To have a news item considered, please

send the information to Drew Champlin,
dchamplin@cahabamedia.com. www.blue-white.com
714-893-8529
5300 Business Dr., Huntington Beach, CA 92649 USA • sales@blue-white.com

p u mp s a n d s y s te m s . com | M a rch 2018

10 NEWS
AROUND THE INDUSTRY
Turbo Lab Names Interim Director
HOUSTON – The Turbomachinery
Laboratory, a center of the Texas A&M
Engineering & Experiment Station (TEES)
and part of The Texas A&M University
System, has named John A. Pappas its
interim director.
Pappas is director of strategic initiatives
for TEES, where he is responsible for
business development and marketing,
operations analysis and managerial
and administrative support. As interim
director of the Turbo Lab, Pappas will
manage operations at the laboratory
and oversee the Lab’s support staff who
plan and execute the Turbomachinery &
Pump Symposia, Asia Turbomachinery &
Pump Symposium and other professional
development initiatives.
Pappas has served as interim director
for TEES’ Texas A&M Energy Institute
and Texas A&M’s National Center for
Therapeutics Manufacturing.
He was also director of the Texas A&M
Wind Energy Center.
Pappas holds a master’s degree in
electrical engineering from the University
of Texas at Austin and is a registered
professional engineer. He was part of the
executive management team of the Center
for Electromechanics at the University of
Texas where he developed high-speed,
high-power generators and power systems,
as well as drive trains for wind turbines.
Pappas has served as program manager,
director of business development and
principal investigator on numerous
projects, attracting tens of millions of
dollars in external funding.
Pappas’ previous positions in private
industry, in the federal government
and as a principal in a successful start-
up company have led to a wide range
of experiences, including research and
development, organization management
and business development.
Dr. Dara W. Childs retired this month
from the director post after more than
three decades with the Turbo Lab at Texas
A&M. The search for a permanent director
is underway.
turbolab.tamu.edu
Endress+Hauser Opens
Third Plant in China
SWITZERLAND – Only five years after
the most recent expansion in China, the
Endress+Hauser Group has once again
March 2 0 1 8 | Pu m ps & S y st e m s
increased production capacity with a third
plant in Suzhou, 100 kilometers west of
Shanghai. The 16,500-square-meter facility
will help the group meet disproportionately
high growth in the Far East.
The opening of the new building, which
is situated in Suzhou Industrial Park, a
450-square-kilometer campus that is
home to more than 20,000 companies,
was celebrated today in the presence
of representatives from government
and business, as well as customers and
employees.
The new plant will give the centers
of competence for flow measurement
engineering, liquid analysis and
temperature measurement engineering
additional capacity.
To date, the Endress+Hauser facility in
Suzhou has been capable of calibrating
flow meters with nominal diameters
between 2 and 1,200 millimeters (mm).
The Group’s largest and most modern
calibration facility is now setting new
benchmarks. In the future, the company
will be able to calibrate electromagnetic
flowmeters in China with a nominal
diameter of up to 3,000 mm with a
maximum measurement uncertainty of
plus 0.05 percent. That corresponds to a
variance of only 100 milliliters (mL) for 200
liters (L) of medium, or one champagne
glass for a bathtub full of water.
us.endress.com
CECO Environmental Dean Pumps
Now Available in Europe
DALLAS – CECO Environmental, a global
provider of fluid handling and air quality
technology and solutions, announced CE
and ATEX certifications for CECO Dean
Pump air-cooled, high temperature RA and
RWA, and heavy duty, high temperature
R4000 series pumps.
The Dean CE/ATEX certifications
make it possible for original equipment
manufacturers and end user customers
in the European Union (EU) to specify and
purchase Dean pumps in local regions.
All certified and compliant pumps from
Dean, now available for importation into
the EU, will feature the “CE” mark, which
makes them compliant with the European
Union’s Machinery Directive 2006/42/EC as
well as the “ATEX” Directive 2014/34/EU.
For clarity, the CE/ATEX-certified pumps
will carry the “CE” and “Ex” marks on
product labeling.
With these certifications, CECO’s high
temperature Dean pumps, as identified
above, now comply with ATEX Directive
2014/34/EU and are available for use
in places where explosive atmospheres
may arise through the mixture of air
and flammable materials such as gases,
vapors, mists and dusts. These conditions
most commonly exist in chemical plants,
refineries, liquid-storage terminals and
latex plants.
cecoenviro.com
PowerWave-Driven Well
Stimulations Kick Off in Colombia
EDMONTON, Alta. – Wavefront
Technology Solutions Inc. announced
that the Powerwave Odyssey Custom Well
Stimulation (POCS) campaign previously
announced for October 17, 2017 in
Colombia has commenced.
Wavefront has been active in
Colombia for more than 40 years and has
approximately 3,000 active producing
and injecting wells in the country. The
POCS are being held in the La Cira field,
where there are approximately 1,400
active producing and injecting wells. The
five-well POCS campaign is expected to
be completed by March-April 2018. Due
to confidentiality, the company cannot
release terms and conditions associated
with the POCS.
One of the greatest challenges in
reservoir stimulation is placing the
treatment fluid where it is needed most.
Wavefront’s POCS approach is achieved
by creating high-energy fluid pulses
that propel liquids deep into the reservoir.
These pulses allow the treatment
fluids to be diverted away from
established flow paths – something
typically not obtainable.
“Increasing global demand for
Powerwave is a key component of
Wavefront’s strategy and we are very
pleased to have this five-well POCS
campaign get underway in Colombia,”
Wavefront president and CEO Brett
Davidson said.
“We are confident that post-stimulation
results associated with POCS will be
as successful as the results generated
elsewhere and will lead to a larger uptake
of Powerwave by the client and other
producers in Colombia.”
wavefront.com
 11

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p u mp s a n d s y s te m s . com | M a rch 2018

12 NEWS
AROUND THE INDUSTRY
MTE Opens New California
Distribution Center
MENOMONEE FALLS, Wisc. – MTE Corporation
announced the opening of a new distribution
center in San Diego.
“At MTE, we don’t just build products
that improve power quality,” said Don
Klein, president of MTE Corporation. “We
build products that are available when our
customers need them. Our new distribution
center significantly improves our delivery and
service levels.”
The facility in Chula Vista, California, has
more than 7,000 products across 200-plus
unique part numbers in stock and ready to
ship on the same or next day. The location
was strategically chosen to service customers
globally due to its proximity to major
ground, sea and air transportation hubs.
MTE Corporation began shipping its MTE and
TEAL branded products out of this facility on
December 4, 2017.
“Our new 23,400 square-foot distribution
center features two key benefits for our
customers” said Z Zakaria, vice president
of business development and product
management. “In addition to access to
major transportation lines, the size of the
facility enables us to stock the wide range
of products that our customers need on any
given day.” mtecorp.com
Shell Announces Deepwater
Discovery in Gulf of Mexico
THE HAGUE, Netherlands – Shell Offshore
Inc. announced one of its largest U.S. Gulf of
Mexico exploration finds in the past decade
from the Whale deepwater well. The well
encountered more than 1,400 net feet (427
MERGERS &
ACQUISITIONS
Xylem acquires EmNet, LLC
February 6, 2018
Xylem Acquires Pure Technologies
February 1, 2018
Mark Tool & Elite Elastomers Form MTE
Joint Venture January 24, 2018
CPV Manufacturing Partners With
ChemFlow Products January 23, 2018
VersaFlex, Raven Lining Systems Merge
January 1, 2018
March 2 0 1 8 | Pu m ps & S y st e m s
meters) of oil bearing pay. Evaluation of the
discovery is ongoing, and appraisal drilling is
underway to further delineate the discovery
and define development options.
“Deepwater is an important growth
priority as we reshape Shell into a world-
class investment case,” said Andy Brown,
upstream director for Royal Dutch Shell.
“Today’s announcement shows how, through
exploration, we are sustaining a strong
pipeline of discoveries and future projects to
sustain this deep-water growth.”
Whale is operated by Shell (60 percent) and
co-owned by Chevron U.S.A. Inc. (40 percent).
It was discovered in the Alaminos Canyon
Block 772, adjacent to the Shell-operated
Silvertip field and approximately 10 miles
from the Shell-operated Perdido platform.
This discovery in a Shell heartland adds to
the company’s Paleogene exploration success
in the Perdido area. Through exploration,
Royal Dutch Shell has added more than one
billion barrels of oil equivalent resources in
the last decade in the Gulf of Mexico.
Shell has three Gulf of Mexico deepwater
projects under construction – Appomattox,
Kaikias, and Coulomb Phase 2 – as well as
investment options for additional subsea
tiebacks and Vito, a potential new hub in the
region. The Shell group expects its global
deep-water production to exceed 900,000 boe
per day by 2020, from already discovered,
established areas. shell.com
Xylem Opens New Pump
Rental Hub in Southeast Asia
CALAMBA, Philippines – Xylem Inc. has
announced the opening of a new pump
rental and service business in Calamba in
the province of Laguna, Philippines. The
hub will serve the growing demand from the
municipal and industrial sectors across the
Philippines and Southeast Asia, particularly
in flood control, mining and power supply
operations. It will also further expand Xylem’s
footprint in the region and build on the
Company’s current manufacturing and sales
operations in Calamba.
Xylem’s Godwin and Flygt brands play a
key role in dewatering and liquids transfer in
municipal and industrial projects, including
mining. As the second-largest mining market
in Southeast Asia, the Philippines has mineral
resources estimated at approximately $1
trillion. With more than 40 large-scale mines
in operation, Xylem’s new pump rental and
service hub will help maximize the efficiency
of mines across the country. Furthermore,
by 2030, $25 billion will be invested in
expanding power generation infrastructure
across the Philippines. Xylem’s new facility is
set to capitalize on this planned investment,
offering technologies to minimize system
downtime at plants. Finally, as the heavily
storm-exposed Philippines faces a growing
threat from tropical cyclones, Xylem’s
hub will offer immediate access to flood
control equipment to protect communities,
infrastructure and industries.
Xylem operates in the global dewatering
space that manufactures, rents, sells and
services its own equipment, providing its
customers with access to a broad range
of reliable dewatering technologies and
solutions. The company has invested
significantly in its international rental
footprint, having recently announced
expansions in Europe, South Africa, the
Middle East and Latin America.
With a wide range of Godwin and Flygt
pumps available for rent, the 2,600 square
meter Calamba hub offers general dewatering
rental services, preventive maintenance,
pump watch, pipeline outsource contacts and
aftermarket services. xylem.com
Engineering Software, Inc.
Launches New Website
LACEY, Wash. – Engineered Software Inc.
has recently launched its new website, eng-
software.com. The newly branded site aims
to introduce and educate customers in piping
and pumping technology innovation. PIPE-
FLO Professional and PUMP-FLO are tools
that capture new opportunities for profitable
growth in multiple disciplines and industries.
Highlights:
• By popular demand, PIPE-FLO Professional
‘Request a Quote’ can easily be accessed in
the navigation bar
• Rapid-response functionality allows
capability with all browsers and mobile
devices
• PUMP-FLO customers can now navigate
their journey by area of interest
• Interactive ‘Press’ search bar filters articles,
case studies, and customer success stories
for easy accessibility
Visitors to the new site can stay informed
with the latest Engineered Software’s industry
news through the ESI News Brief subscription.
The ESI News Brief contains richer online
content such as technical tips, industry news,
featured product information and articles
written by ESI’s senior engineers. This
content will also be contained in online press
pages. eng-software.com
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Circle 103 on card or visit psfreeinfo.com.
14

From the Readers

J A N UA R Y 2 0 18
PUMPSANDSYSTEMS.COM JANUARY 2018 The author responds flow, B: 75 percent duty point flow, C: 50
The Leading Magazine for Pump Users Worldwide

Reader responds to percent duty point flow and D: 25 percent

Dear Mr. Ruiz,
“True Weighted Efficiency: duty point flow, without the use of a
A Different Method for Thank you for your feedback.
2018 Comparing Pumps” First, I will address your question about control valve. Those examples are based
GLOBAL MARKET ANALYSIS
2 TO 4 PERCENT
GROWTH EXPECTED

the system curves outlined in Figure 1. on a constant system curve with a 30

percent Hsh0 static head.
PROTECTING CRITICAL ASSETS
CYBERSECURITY IN IIOT

Each system curve is a representative

FILLING IN THE SKILLS GAP

Lee Ruiz, Oceanside,

RECRUITING,
EDUCATION, TRAINING

Finally, the system curve with the

SPECIAL SECTIONS
FOOD & BEVERAGE

system curve that does not include a

AND HVAC

CA writes:
control valve. Therefore, the first system static head equal to the 100 percent
I like the idea of using both power and duty point head is intended to illustrate
curve with zero static head considers a
time duration (P x t = energy) for the True a control curve for a constant pressure
hypothetical friction based system. The
Weighted Efficiency (TWE) evaluation. I system. Indeed, a constant pressure
next two system curves are based on a
would expect the methodology outlined in system as shown would typically require
hypothetical system with the static head
the article and summarized in Equation 5 to a control valve and a VFD to accomplish
set at 30 percent and 60 percent of the
become universally accepted and used. that level of control.
duty point condition. Once again, these
Background information and method In any case, the weighting factors
system curves are fi xed system curves
development are both informative in Table 1 may be applied to depict the
and do not consider the influence of a
and understandable. However, Figure 1 energy consumption of the pump at those
control valve. The system curves in Figure
seems to be somewhat troubling operating conditions.
1 are shown to illustrate the different
to understand. In summary, I believe the paper is
weighting factors in Table 1, as a function
Four system curves are shown as technically correct. However, reader
of the static head at 0 percent Hsh0, at 30
starting from different static head values; feedback is always appreciated and I could
percent Hsh0 or at 100 percent Hsh0.
then, all four pass through one duty flow make a few clarifying points to improve
Figures 2 and 3 are intended to show
rate and head point along a single-speed the understanding of the graphics and the
how the VFD is used to adjust the pump
pump curve. TWE methodology.
operating speed to achieve the operating
There is no mention of a control valve
conditions at A: 100 percent duty point Trygve Dahl, Intelliquip Inc.
and Figure 1 is labeled as variable speed
pump performance.
For a variable speed pump, I would D E C E M B E R 2 0 17
PUMPSANDSYSTEMS.COM
DECEMBER 2017 Final Tier 4 engines themselves are
SYSTEMS
normally expect changes in static head The Leading Magazine for Pump Users Worldwide
Reader responds to not typically larger than Tier 3, but
POWER “A Smooth Transition the overall engine package might very
to result in the same-shape system curve GENERATION
to be moved up or down accordingly,
Prevent problems by
planning prior to purchase to Final Tier 4 (FT4) well be larger as additional emissions
providing there are no additional control Diesel Driven Pumps” components are likely fitted around the
valve compensations. I would further carryover engine from Tier 3.
PUMPS IN THE SPOTLIGHT:
HURRICANE DEWATERING
John Fischer,
expect a corresponding head value to The diesel combustion process
6 POINTS OF
SEAL FAILURE

Engine Consultant,
Consultant
& HOW TO AVOID THEM

SPECIAL SECTION:
PRODUCT SHOWCASE

intersect the speed curve required for a Palatine, IL writes: occurs when air is compressed to very
desired flow rate. high levels (fuel as a liquid would not
The author of this article provides a great compress) and at the opportune time,
If the above is correct, then the third
bulleted paragraph on page 56 may need foundation for understanding diesel diesel fuel is injected and ignites. The
to be revised. Even though the static head engines and emissions requirements, electronic fuel injection being used
is 100 percent of 54 feet, a non-constant and I’d like to offer some supplementary on most diesel engines these days
system curve would still rise as flow rate information. allows for very accurate injection and
increases. The variable frequency drive Most of the Tier 4 Regulations, greater power. Basically, if the internal
(VFD) pump speed would then change to which vary depending on the mechanical components of the engine
obtain the desired flow rate. Further, in horsepower (hp) of the engine, have can take it, if you want or need more
Figures 2 and 3 on pages 58 and 59, the actually taken affect and any purchases power you simply inject more fuel.
230-gpm flowrate may not be achievable (unless perhaps from carryover engine Finally, diesel exhaust fluid (DEF) is
at full speed for pumps A and B if the inventory) should be with compliant quite stable and if it is stored indoors
static head is 54 feet and a control valve is engines being supplied from the at “room temperatures,” one should not
not used. pump company. have any trouble with degradation.

March 2 0 1 8 | Pumps & S y stem s

Circle 109 on card or visit psfreeinfo.com.
16 PUMPING PRESCRIPTIONS
Middle East: What’s New with Water
Pumping Challenges in Israel?
T
his column takes us beyond the
boundaries of traditional U.S.
pumps and pumping systems I
have covered before by looking across
the ocean to the Middle East pumping
practices, differences and similarities. I
will discuss some of the inner workings
of the Israeli water infrastructure and
its attention to pump efficiency and
pumping system reliability.
Bird’s Eye View
In Israel, nearly all water is publicly
owned. The state acts as the legal
guardian and manages the water in the
best interest of the public. According
to information from OECD.org, water
reforms have shifted the responsibility
for water treatment from municipalities
to water companies on the municipal/
regional level. The reform was intended
to increase efficiency.
Concerns about water scarcity, climate
change and environmental protection
have prompted reforms to build seawater
desalination plants, which significantly
change traditional north to south
geographical water allocation, according
to OECD.org. Some of these efforts are
paralleled in the U.S. by legislative-aimed
processes to establish pump efficiency
standards and regulations.
The yearly production of water in
Israel is 2,000 million cubic meters (50
billion gallons) and almost equally comes
from three sources: Jordan River and
underground reservoirs, desalination
plants and wastewater.
Practical Operational Structure
As the water industry shifts toward
privatization, the trend is to gradually
shift management of local water
March 2 0 1 8 | Pumps & S y stem s
By Lev Nelik, Ph.D., P.E.
Pumping Machinery LLC, P&S Editorial Advisory Board
resources from the municipalities to
privately subcontracted water companies.
One of the largest water companies in
Israel is the governmental Mekorot
National Water Company. The activities
of the company are derived from a
law that authorizes Mekorot both as a
supplier of water and as the national
water authority.
Mekorot supplies 90 percent of Israel’s
drinking water and 70 percent of the
country’s total water consumption.
The company delivers water to the
urban, industrial and agricultural
sectors, as well as to the Hashemite
Kingdom of Jordan and the Palestinian
Authority under commitments made in
international agreements. With Israel
being roughly half the size of New Jersey,
the logistics of the water infrastructure
has some similarities with the watershed
management by state and county
governments in the U.S.
Mekorot operates approximately
3,000 water supply, water treatment,
infrastructure, wastewater treatment,
desalination and other facilities
throughout Israel. The company
oversees 664 stations, 30 brackish
was desalination facilities, 10,500 km
of waterlines, 635 concrete and steel
pools larger than 500 cubic meters, six
laboratories, and eight operating and
control centers.
Pumps
Most of the water pumps in Israel are
vertical turbine types, and a smaller
percentage is single stage double suction
types. This is reflective of the general
topographical terrain of Israel—rapid
transition from the desert plan to
mountains. Significantly higher pump
heads are required in Israel generally
than in the U.S., although some
similarities exist.
Even for a rough estimate, based
on the numbers presented above, the
50 billion gallons of water per year, if
assumed equally distributed between
some 3,000 pumps in Israel, an average
pump moves 2,000 gallons per minute
(gpm). If one further assumes 100
pounds per square inch (psi) developed
pressure for such typical pump (230
feet of head), a typical motor power
would be 2,000 x 230 x 1.0/3,960/0.80 =
150 horsepower (hp), with an assumed
average efficiency of 80 percent.
That is, of course, an “average” picture,
a very rough ballpark estimate, and some
of the vertical turbine pumps in Israel
are at much higher horsepower (hp),
with some as high as 6,000 hp. With
that, one can estimate the total energy
consumption of these pumps being
nearly 150 x 3,000 x 0.746 = 350,000
kilowatt (kW) = 350 megawatt (mW),
or roughly a 20 percent of all electrical
power generated in Israel. In other words,
the energy supplied for the water needs
is very significant. At an assumed cost
of $0.10 per kW, this translates to $500
million per year. Thus, saving even 1
percent of this energy through pump
efficiency improvement would save the
country nearly $3 million per year.
Not surprisingly, the efficiency
improvement programs are taking more
attention at all levels of infrastructure—
geopolitical, environmental, technical
and economical.
The approach to efficiency
improvement is through field study of
actual operating pumps and determining
the actual efficiency versus original
 17

equipment manufacturer (OEM). The

resultant data is processed, and a new
impeller is designed specifically for new

GRINDER
DUAL SEAL
or updated flow conditions, making a
replacement of the entire pump to fit
new operating conditions unnecessary.
The pump’s BEP is shifted, resulting in
increased efficiency and better reliability.
Such an approach is obviously
advantageous for cost savings, since there
is no impact on piping modifications
usually associated with pump changeovers,
foundation modifications, etc.

Summary & Conclusions

Customized design of pump impeller
hydraulics is gaining momentum at all
installations around the world, especially
for the pumps with significant energy
levels. In Israel, this trend is further
enhanced by the regulations that are
applied by the government agencies as a
mandate to apply methods and technology
to conserve energy and pump water in
the most effective and efficient way, with
minimum expenditures avoiding entire
pump changeover.
In upcoming columns, I will offer
PROTECTS
Two mechanical seals, coupled with sensor probe and seal leak detection
updates on what is going on in Israel as
circuitry in the panel, provide double the protection for your investment,
well as developments from other parts
extending the life of the pump.
of the world. Please send me comments
about similar efficiency programs that are

DUALTHREAT
happening where you live.

Dr. Nelik (aka “Dr. Pump”) is president of

Pumping Machinery LLC, an Atlanta-based
firm specializing in pump consulting, GRINDS
Circle 120 on card or visit psfreeinfo.com.

training, equipment troubleshooting A high-torque 3450 rpm motor powers our patented cutting system that
and pump repairs. Dr. Nelik has 30 years grinds at 414,000 cuts per minute. This dual threat combo efficiently
of experience in pumps and pumping pumps sewage slurries up to 130 feet.
equipment and he is also a director
of the International Center for Pumps
Technology Research and Development
in Israel, covering pumps news in the
Middle East. He may be reached at pump-
magazine.com. For more information, visit
pumpingmachinery.com/pump_school/ franklinengineered.com
pump_school.htm.

p u m p s a n d s y s t e m s . c o m | M a rch 2018
18 PUMP SYSTEM IMPROVEMENT

By Ray Hardee
Engineered Software Inc.

Proper Pump Selection:

Avoid Oversizing Your Pumps
By Dominik Fry, P.E
Engineered Software Inc.

Editor’s Note: Dominik Fry is a member of regardless of the pump’s specific quality. All pumps have a design point where
Ray Hardee’s team at Engineered Software A pump made from titanium and the efficiency is maximized, called the
Inc. This month, he is a guest columnist in designed for a 30-year life cycle, whilebest efficiency point (BEP). This is where
Hardee’s place. expensive, could perform inadequately the pump runs the smoothest and radial

P
for another industrial application. forces are minimized. The further away
roper pump selection is more Therefore, it is crucial to fit the right
from the BEP, the higher the radial loads
important than ever, with pump to the right application. To on the pump. The pump will generally
drastic consequences for understand why failure can occur, let’s have a critical speed around 25 percent
maintenance, reliability and efficiency. dig into the basic operating points of over the BEP where its natural frequency
The selection process remains difficult centrifugal pumps. is reached and excessive vibration may
for average users, and even contracting occur. The pump will essentially shake
the work to a reputable itself apart, first going
engineering firm does through the wear ring, then
not guarantee success. the seals and finally the
In this column, we will The performance of individual bearings. This is usually easy
cover centrifugal pump pumps is a combination of the pump to spot since the pump will
design, common pitfalls in vibrate and may begin leaking
the selection process and design and the operating conditions. fluid far before any scheduled
consequences of maintenance.
improper selection.
Centrifugal pump Pump Reliability
technology has been around Pump curves demonstrate the
for centuries without any revolutionary Pump Design strong relationship between pump life,
changes. There are new alloys and As the pump shaft spins, it turns the pump reliability and where the pump
coatings to build the casings and impeller inside the casing, which adds operates on its curve.
impellers from, and efficiencies have energy into the process fluid. This allows The performance of individual pumps
increased. Bur the basic design remains the impeller to act as a cantilever with is a combination of the pump design and
largely unchanged. Unlike other 21st a wear ring, seals and bearings that the operating conditions. The pump’s
century technologies, a centrifugal keep everything in place and fluid from performance data is provided to the user
pump from 100 years ago is nearly leaking out. The spinning impeller in the form of pump curves, with the
identical to modern designs. If anything, changes the incoming fluid’s direction, primary function to communicate or
the older designs are more robust, which can cause intense radial loads on define the relationship between the flow
with the current competitive market the pump. The bearings not only reduce rate and total head for a specific pump.
forcing manufacturers to cut costs by rolling friction, but also support the They are provided by the manufacturer
eliminating excess material. pump shaft and absorb these radial loads. and show the operating characteristics
A pump from a reputable manufacturer This may be seen in a detailed view of a of a specific pump type, size and speed
may perform poorly in a system centrifugal pump in Image 1. based on results of standardized tests

March 2 0 1 8 | Pumps & S y stem s

Experience. Reliability.

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Centers located within just a few hours’ drive of most customers,
Flowserve can quickly respond to help you resolve plant issues
and keep you up and running more reliably than ever.

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• the skills and tools to fix individual assets for
reduced downtime,
• broad engineering experience to increase efficiency,
• or long-term service contracts and lifecycle agreements
to increase productivity,

Flowserve is your reliability partner.

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© 2018 Flowserve Corporation
20 PUMP SYSTEM IMPROVEMENT
Image 1. Detailed view of a centrifugal pump (Images courtesy of the author)
and test conditions. A healthy pump
maintains the defined relationship
between the head and flow at all times.
The pump curve is required for:
• Proper pump selection. Using a
pump curve will ensure the pump
selected is matched to the system
requirements.
• Monitoring the health of the pump.
If the pump is not operating on the
published curve, something is wrong.
• Troubleshooting the operation of
the entire piping system. The pump
provides energy into the system,
and knowing the energy going in is
a critical clue for identifying issues.
Without a pump curve, it is extremely
difficult to determine what is causing
a problem in the system and what
should be done to correct the problem.
For accuracy, it is critical to have a
pump curve for every pump.
Image 2 shows a stylized pump curve
in black with efficiency in green. To
operate at the BEP, the system must
either control the pressure at the outlet
of the pump or the flow through the
system to keep the pump operating point
(indicated by the red arrow).
For example, if the system causes the
pressure at the discharge to surpass the
March 2 0 1 8 | Pumps & S y stem s
pressure at the BEP, the operating point
will move to the left up the curve and
flow will reduce. If the system causes
the pressure at the pump’s discharge
to drop, the operating point will move
down and to the right. Moving to the
left or right of the BEP causes forces on
the impeller to increase, and these forces
cause stresses that have a significant
negative effect on the life and reliability
of the pump.
If we overlay the expected life of the
pump as a function of where the pump
is operating, we get a “Barringer Curve,”
which shows the mean time between
failure (MTBF) as a function of BEP flow
rate. This curve was created by Barringer
& Associates in a study of seal failures in
centrifugal pumps.
Using Image 2, the closer the pump
is operated to its BEP, the greater the
MTBF. As the operating flow rate of
the pump moves farther to the left or
right of the BEP, the failures occur
more frequently.
MTBF cuts in half when the pump
is running 20 percent below the BEP
or 10 percent above it as shown. When
operated to the left of the BEP, problems
like high temperature rise, low flow
cavitation, bearing problems, reduced
impeller life, suction and discharge
recirculation lead to seal failure and
pump downtime. To the right of the BEP,
bearing and seal life are effected, and
cavitation problems occur.
The key takeaways are understanding
how the system impacts the pump on its
curve and the reliability and life of the
pump increases when the pump operates
near the BEP.
Pump Cavitation
Cavitation is a major concern; it can
demolish pumps very quickly. If there
is a low intake pressure or the pump is
operating at the far end of its curve, it
pulls the fluid through so rapidly that
the fluid pressure drops below its vapor
pressure and can cause it to boil.
For example, at sea level water boils
at 212 degrees Fahrenheit (F). At the
top of Mount Everest, where the pressure
is much lower, water boils at 160 F. In a
pump, the pressure may drop low enough
that water “boils” at 60 F, or whatever the
ambient temperature may be.
It may seem difficult for air to strip
away steel in a pump. In fact, it is the
millions of vapor bubble creations and
implosions that can do the damage.
This effect is clear once the pump is in
operation and can sound like gravel being
pumped no matter the base fluid. For
this reason, spending extra money on an
oversized pump may cost more money in
maintenance and repairs.
Design Process
Because the individual piping process
is generally unknown, engineers tend
to oversize pumps. They do not know
exactly how a contractor will route
pipes and thus include a safety factor
in the calculations. This safety factor
generally goes on top of the worst-case
design scenario.
The engineering firms are incentivized
by the fact that they do not want to
be blamed for an undersized pump
if it is not able to meet the process
requirements. Imagine the outrage
and damage to a firm’s reputation if
Yea, it’s kind of like that.

Designed to chop and macerate solids

in extremely challenging waste water
applications

Excellence in Innovation

www.cranepumps.com

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22 PUMP SYSTEM IMPROVEMENT
% Head
% Flow
Image 2. Pump curves and reliability
their clients did not get adequate water
pressure from a shower, cooling from the
heating, ventilation and air conditioning
(HVAC) or flow from the sewers.
A general rule of thumb for safety
factors is 10 percent. The junior engineer
will generally assume a certain amount
of required energy based on the expected
piping, process and control elements, and
then add 10 percent to this number.
A senior engineer may review the
work and add an additional 10 percent
as well. Things continue to get more
complicated as end users may have
unrealistic expectations for production
capacity given the desired high numbers,
or may want the infrastructure in place
for a potential expansion years down the
road. When the pump is finally ordered,
the manufacturer’s representative will
help select a pump that is large enough to
handle these operations and then some.
These safety factors end up
compounding on each other leaving the
actual process something different than
what was required.
The end user may be saddled with
an inefficient pump and the possibility
of hundreds of thousands of dollars in
additional energy and maintenance.
March 2018 | Pumps & Systems
Mean Time Between Failure
This is why using software to model
expected flow conditions at various
operating points is highly recommended.
Real World Results
According to the Hydraulic Institute’s
“Pumping System Optimization,” an
evaluation of 1,690 pumps at 20 process
plants discovered some alarming
results. They found the average pumping
efficiency to be below 40 percent. On
top of that, more than 10 percent of
pumps from that study were less than 10
percent efficient.
A major cause was found to be
improper pump selection. The general
rule is that a pump and motor combo will
cost about $1 per day, per horsepower of
the motor.
While energy costs vary by location,
this is a good starting point to begin
understanding what potential costs you
are facing.
For larger horsepower pumps running
inefficiently, the wasted capital is
staggering. Energy costs alone are
seldom cause for change, much less
transformation of an industry.
Once the pumps are installed and
running, the energy costs are out of
sight and out of mind. There are many
other costs in industrial facilities, and
discovering the true cost of the pump
is hard when it is buried in an
industrial energy bill alongside the high
costs of heating, cooling and running
the equipment.
There are additional benefits from
an optimized system than just energy
savings—process quality and quantity
for starters. In many instances, systems
have been left alone, because they work
and managers do not want to endanger
the process.
This works if you are satisfied with
the status quo. However, slight changes
to the system may result in sizable
increases in production throughout.
When considered over many years, these
changes produce dramatic results.
System reliability and reduced
maintenance generate some of the
biggest savings when the pumping
system is running correctly.
From the Barringer curve, we can
see that we must operate close to the
pump’s BEP in order to maximize our
efficiency and mean time between failure
of the pump.
Reputable pump manufacturers design
their pumps to operate for 20 or more
years of operation if done correctly, yet
end users are often satisfied with just
five years. Costs are also easier to track in
parts and labor. The savings opportunity
from better maintenance and reliability
alone warrants a second look at your
pumps and systems.
Dominik Fry, P.E. is Engineered
Software’s business development engineer
and has nearly a decade of experience
in the energy industry. Fry earned a
Bachelor of Science at Montana
State University and his
professional engineering
license in mechanical
engineering from the state
of Colorado.
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24 COMMON PUMPING MISTAKES

By Jim Elsey
Summit Pump Inc.

A Centrifugal Pump Primer

Last of two parts

Editor’s Note: In the February 2018 indicate 1 pound of pressure on a gauge at

issue of Pumps & Systems, we covered head in feet the base. Note this will vary slightly with
x SG = PSI
the simple physics and conservation of 2.31 temperature and gravitational field.
energy phenomena occurring in the pump Equation 2
casing, where the impeller-generated fluid Horsepower
velocity is converted to pressure in the It requires a defined amount of power
pump casing. We also discussed why pump to pump a defined amount (weight) of
manufacturers use the term “head” while PSI x 2.31 fluid to a selected height or distance
= head in feet
operators will be concerned with pressure. SG within a fi xed unit of time requires a
The simple explanation for using head defined amount of power. We can see the
Equation 3
instead of pressure is that the pressure from relationship by looking at the formula
a pump will change if the weight/specific
gravity (SG) and or temperature of the liquid pumping a fluid other than water, please
changes, but the head will not change. We consult with the manufacturer to have head x flow x SG
BHP =
also covered how most pump problems occur them “correct” the curve for the fluid you 3,960 x efficiency
on the suction side and that you should will be pumping. Equation 4
always operate a pump as close to the best Equations 2 and 3 show how to convert
efficiency point (BEP) as is possible. from head to pressure or vice versa.

S
For an example, consider three
pecific gravity (SG) is a ratio of two identical pumps each pumping a different for calculating brake horsepower (BHP).
different fluid densities. We use the fluid. Each pump has the same impeller See Equation 4. For centrifugal pumps in
SG (1.0) of water as the base fluid, diameter, the same speed and the same US-C units:
so we are comparing all other liquids system curve. Pump A is pumping water • head in feet
to water. SG equals density of a liquid with a SG of 1.0. Pump B is pumping a • flow in gpm
divided by the density of water. light hydrocarbon with a SG of 0.7 and • efficiency expressed as a decimal
Since every fluid can have a different pump C is pumping an acid of SG 1.23.
SG due either to its inherent properties or Assuming all three pumps were rated In the formula, flow and head both
the temperature when it is being pumped, for 115 feet of head, they would produce have a direct relationship on the
pressure is not a convenient method 50 pounds per square inch (psi) for pump horsepower required. Any increase in
to select and size the pump. However, A, 35 psi for pump B and 61 psi for pump flow or head will increase the horsepower.
since the developed energy/head is C, but all three pumps would produce 115 The opposite is also true. The SG also has
predictable and constant regardless of feet of head. An antithesis example would a direct relationship on the outcome.
the fluid pumped, industry professionals be if the pumps were selected and rated The efficiency of the pump is expressed
use head to describe/predict the pump for 100 psi. Then pump A with a SG of 1.0 as a decimal and is the efficiency at the
performance. Also when using head, we would produce 231 feet of head, pump B selected head and flow in the numerator.
can provide one performance curve per with a SG of 0.7 would produce 330 feet You will need to determine this efficiency
pump for different fluids at different of head and pump C with a SG of 1.23 from the manufacturer’s performance
temperatures. If we used pressure, would produce 187 feet of head. curve. Note the inverse relationship with
we would need an infinite number of I am frequently asked where the efficiency. An increase in efficiency will
curves. Most pump performance curves conversion factor 2.31 derives from. A reduce the required horsepower.
are based on water at approximately 2.31- foot vertical column of water at Final note on this algebraic formula
68 degrees Fahrenheit (F). If you are ambient temperature (SG of 1.0) will for BHP: it can be solved for any one

March 2 0 1 8 | Pumps & S y stem s

 25

unknown if you know the other variables.
For example if you already knew the BHP,
but did not know the efficiency, you could
set up and solve for that unknown. In
the field, I frequently use this formula to
solve for the flow rate.
How Does the Fluid
Get to the Pump?
Many people mistakenly believe that
centrifugal pumps suck the fluid from
the suction source. There must be some
other energy source to deliver the
fluid to the suction eye of the impeller.
Fluids have no tensile strength, and the
impeller is not capable of reaching out to
pull the fluid into the pump (regardless
of manufacturer). From a full bucket of
water, reach in and grab the water with
your hand and attempt to pull/lift the
fluid to another container, and all that
happens is your hand gets wet.
Note of acquiescence: When the pump
impeller is turning at operating speed,
the fluid velocity is changing in front of
the impeller eye. This velocity change
does induce a small differential pressure
at the inlet of the impeller.
Some other force must move the liquid
in the suction system to the impeller
eye. Often, this other force is gravity
because the source of supply is at a
higher elevation than the pump suction.
There may also be pressure involved. In
the event of a lift situation where the
pump is above the source of supply, it is
atmospheric pressure pushing down on
the fluid surface that supplies the energy.
The limits of atmospheric pressure as
a suction supply force therefore are 34
feet of “lift” if the pump is at sea level.
Atmospheric pressure is 14.7, and 14.7 psi
X 2.31 is about 34 feet. However, due to
friction, imperfect systems, air ingress
and liquid vapor pressure, most pump lift
capabilities are limited to 25 feet or less.
References
Cameron Hydraulic Data Book
Jim Elsey is a mechanical engineer
who has focused on rotating
equipment design and applications for
the military and several large original
equipment manufacturers for 43 years
in most industrial markets around the
world. Elsey is an active member of
the American Society of Mechanical
Engineers, the National Association of
Corrosion Engineers and the American
Society for Metals. He is the general
manager for Summit Pump Inc.
and the principal of MaDDog Pump
Consultants LLC. Elsey may be reached
at jim@summitpump.com.

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p u m p s a n d s y s t e m s . c o m | M a rch 2018
26 SPECIAL SECTION CHOPPER & SHREDDER PUMPS

Shredder Pumps Solve

Contraband-Created Problem
in Correctional Facility
Foreign materials in sewage system led the maintenance team to look
for a new equipment option.

BY KEITH GRGURICH & GARY BROWN

BJM PUMPS

W
e have all seen it in movies—prison inmates cloth remnants and other debris had been frequently clogging
sneaking cigarettes and other contraband the grinder pumps.
from one person to another while guards are To alleviate the excessive clogging, the in-house
not looking. While these scenes from cinema maintenance team at the correctional facility installed catch
may be highly dramatized, the reality is that goods do get baskets on the in-flow pipes. These baskets, which were
smuggled throughout prisons and correctional facilities. designed with spikes to catch the large pieces of tape and
One correctional facility in the Great Plains region garbage, had to be manually cleaned out three times each
had to deal with the very week. This was an absolute
real consequences of nightmare for the in-house
smugglers’ tape being flushed maintenance staff.
down toilets. The staff talked with
While there was great An additional lip seal is their plumbers and together
effort made to restrict the they decided to look for
flow of contraband, this installed above the impeller different styles of pumps
correctional facility struggled to help prevent unwanted that could reliably handle the
to keep unwanted materials wastewater without clogging.
from entering the sewage materials from entering the They discovered submersible
system. Tape, pieces of mechanical seal chamber. shredder pumps and selected
cloth and other evidence of one for the following reasons:
contraband smuggling were The main pumps are
being flushed through the engineered to shred solids.
septic system and made their They use a cutting impeller
way into a wastewater sump design with a tungsten
outside of the correctional facility. The wastewater sump carbide tip to continuously rip solids against a tooth-edged,
had relied on two grinder pumps in a duplex arrangement spiral-shaped cover plate. With 360-degree shredding action
to transport the raw sewage from the correctional facility and non-clog, two vane impellers, the pumps can shred the
through the sewer system to the local municipal wastewater tape and other fibrous materials that were being flushed
treatment plant. The problem was that the smugglers’ tape, through the correctional facility’s sewage system.

March 2 0 1 8 | Pumps & S y stem s


Proven to handle solids up to 3.5 inches in size, the new
equipment could pump wastewater at 570 gallons per minute
with a maximum of 54 feet of head.
With a motor housing manufactured from 304 stainless
steel, the pump is more resistant to corrosion and lasts
longer than pumps with cast iron, steel or aluminum
motor housings.
The submersible shredder pump is constructed using a
hardened ductile iron impeller and suction cover that can
withstand pumping solids-laden wastewater—unlike pumps
with standard cast iron or plastic components.
The pump’s motor is protected by double mechanical
seals and an additional lip seal. In the double mechanical
seal design, the lower seal faces are made of silicon carbide/
silicon carbide and the upper seal uses cooler running carbon/
ceramic. An additional lip seal is installed above the impeller
to help prevent unwanted materials from entering the
mechanical seal chamber.
The pump also uses motor overload protection and (NEMA)
Class F motor insulation. If the motor temperature or amp
draw becomes too high, the motor overload switch “opens”
and turns the pump motor off. The switch automatically
resets when the motor cools, and the pump resumes
its operation.
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27
The correctional facility purchased two submersible
shredder pumps in addition to slide rail assemblies. The slide
rail assemblies were installed to make sure the in-house
maintenance team could easily pull the pumps for future
inspection and maintenance as needed.
The slide rail assemblies and pumps were installed into the
correctional facility’s wastewater sump in June 2015 and have
been running well since their installation. There have been no
clogging problems, and the in-house maintenance team was
able to remove the catch baskets at the in-flow pipes.
When you have a pump that is clogging frequently, you
may not have the right pump for your specific application.
Frequent clogging can cause headaches and waste precious
maintenance dollars. On the other hand, when your pumps
are working the way they are supposed to, it frees up your
maintenance team to focus on other demands throughout
your facility.
Keith Grgurich is director of sales at BJM Pumps and Gary
Brown is the midwest regional sales manager at BJM Pumps.
For more information, visit bjmpumps.com
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p u m p s a n d s y s t e m s . c o m | M a rch 2018
28 SPECIAL SECTION CHOPPER & SHREDDER PUMPS

Choppers Find Creative

Use as Conditioning Pump
A different element contributed to the de-clogging of a wet well.

BY DEREK VAUGHAN
VAUGHAN COMPANY

CHOPPER PUMP APPLICATIONS

T
he Otay River Pump Station (ORPS), which pumps 7
to 9 millions of gallons per day (mgd) of raw sewage
to the South Bay Water Reclamation Plant for water
recovery, had a problem in the 50-foot long by 10-foot
wide by 30-foot deep wet well. A floating blanket of grease
and debris, sometimes as thick as 4 feet, would occur on a
regular basis.
The City of San Diego had been contracting two vacuum
trucks to clean out the station every three to four months at a
cost of approximately $50,000 to $100,000 per year. Since the
city has had good experiences replacing their clogging non-
clog pumps with chopper pumps, they turned once again to a
chopper pump company for a more cost-effective solution.
Chopper pumps can be ideal for use in pump stations
and lift stations as conditioning pumps. When used as a
conditioning pump, a submersible chopper is fitted with a
nozzle to provide high-velocity mixing and is placed in the
problem wet well on a portable stand.
The purpose of the conditioning pump is to recirculate and
chop the contents of the wet well. Recirculating the wet well
contents through a chopper pump chops and mixes the grease
and debris that can accumulate as a floating layer, and chops
and re-suspends heavier debris that can accumulate on the
wet well floor.
This homogenization of the wet well contents not only
prevents buildup of grease and debris in the wet well, but also
helps prevent clogging of the non-clog pumps typically used
as dewatering pumps for these stations.
For ORPS, the chopper pump company selected an 8-inch
submersible chopper pump with a 25 horsepower (hp), 1,200
rotations per minute (rpm) motor with mixing nozzle and
portable stand. In 18 months of use with the conditioning
pump, the wet well has not required cleaning. Based on the
cost of the pump and installation, the pump paid for itself in
just two-and-a-half months of use.
In San Diego, a submersible chopper pump
was used in pump stations and lift stations. A
chopper pump can be used in many industries and
applications, including:
• Wastewater handling, including raw sewage, septage,
clarifier scum pits, return and waste-activated
sludges, and digester mixing
• Food processing, where chopping and pushing
through byproduct elements that can clog a system,
including feathers, fat and other organic materials
is required
• Automotive and steel industries, to handle
byproducts including metal chips, oil washdown
and iron ore pellets
• Contractor businesses, to handle hazardous waste
and storage tank cleanup
• Chemical and petrochemical facilities, to disperse
latex skins and sulfur froth, keep storm drains clear
• Other industries, such as sand and gravel, steel,
paper and wood products.
Derek Vaughan is domestic sales manager for the Vaughan
Company, a U.S.-based manufacturer of chopper pumps.
During his 14-year career with the company, Vaughan
has worked in a variety of roles, from a hands-on pump
assembler to business development. For more information,
visit chopperpumps.com.

March 2 0 1 8 | Pumps & S y stem s

 CHOPPER & SHREDDER PUMPS SPECIAL SECTION 29

Reversing Grinder
Pumps Prevent Clogging
on Randall s Island
A retrofit brought reliability to the island s wastewater system.

BY STEPHEN DOOLITTLE
ZOELLER ENGINEERED PRODUCTS

R
andall’s Island in New York City encompasses 433
acres on the Harlem and East Rivers, between
Manhattan and Queens. It is a well known location,
having been used for a variety of purposes over the
past 350 years. In 1992, an alliance of dedicated New Yorkers
saw its potential as a great recreational resource for the
city’s residents.
Since then, it has become the premier destination for
sports and recreation, including 60 athletic fields, a golf and
tennis center and Icahn Stadium, a world-class track and field
facility. It has also become a popular event site for hosting
concerts, art fairs and cultural festivals.

The Problem
The island is also home to the New York Department of
Environmental Protection’s Wards Island Wastewater
Treatment Plant. The island is serviced by a collection system,
which includes numerous small pump stations. Being a year-
round attraction, its 3 million annual visitors depend on its
wastewater collection system and associated facilities.

A few years ago, some submersible Image 1. Removal of existing clogged pump (Images courtesy of
Zoeller Engineered Products)
pump stations began to experience
A few years ago, some submersible pump stations began to
regular clogging problems, experience regular clogging problems requiring emergency
requiring emergency repairs. repairs. The operators and service providers were looking for
a solution when Gary Smith of G.T. Smith & Associates of
Laurel Springs, New Jersey, became aware of the problem.
He suggested that a unique product might be able to

p u m p s a n d s y s t e m s . c o m | M a rch 2018
30 SPECIAL SECTION CHOPPER & SHREDDER PUMPS
alleviate the problem and be retrofitted
into the existing system.
The ability to use the existing system
while updating to a more modern
product was intriguing, and they wanted
to know more.
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March 2 0 1 8 | Pumps & S y stem s
The Solution
Information was provided that detailed
a specially-designed grinder pump.
The pump manufacturer noted that
grinders have successfully handled
many problem applications that cause
Image 2. Installation of new pump
traditional solids handling and grinder
pumps to struggle. The design of this
particular product incorporates rotating
blades that cut axially as the solids are
being pulled through a stationary flat
grinder plate, designed with a unique
pattern of slots and orifices. The cutter
and plate are each made of 440C
stainless steel hardened to a Rockwell
HRC 58 “cutlery” steel that is considered
the strongest and most desirable knife
making material.
The benefit of this design is not
only its ability to cut up solids in the
waste stream, but also its change in
direction of the rotating blades with
each cycle. During an operating cycle,
it cuts clockwise, then reverses course
and cuts counter-clockwise during its
next cycle. The bi-directional cutting
action operates in this manner of
reversing cutting direction each time
it is called on to pump. Operating in
this manner keeps the cutting surfaces
clean and prevents roping of materials
 31

after 14 months of operation. In

the wake of the success of the
new Randall’s Island system, two
additional sets of these pumps
and reversing boxes were ordered,
retrofitting two more stations at
the site.
Stephen Doolittle is Zoeller Engineered
Products’ marketing manager. He may be
reached at steved@zoeller.com or 800-928-
7867 ext. 8215. For more information, visit
zoellerengprod.com/en-na.

from occurring, which is what often

occurs and leads to a clogged pump. As
an added feature, this product was able
to be retrofitted onto the existing rail
system and operate from the existing
control panel.
In July 2015, two 5 horsepower (hp)
grinder pumps and a reversing box
were purchased. When the system was
installed and started up in September,
the pump manufacturer received
positive feedback on the user’s operation
with no clogging occurring during the
first few months of operation. While
that was good news, success could not be
claimed until the pumps went through a
full year’s cycle of operation.
After a year of operation, the pump
manufacturer inquired into the status
of the application to see how the pumps
had been performing. While it was
reported that the original Randall
Island’s pumps were clogging on a
regular basis, the reversing grinder
pumps had not failed to perform even
Circle 127 on card or visit psfreeinfo.com.

p u m p s a n d s y s t e m s . c o m | M a rch 2018
32 SPECIAL SECTION CHOPPER & SHREDDER PUMPS

Manhole System Replaces

Failing Grinders in Travel
Center Chain Facility
With frequent clogging problems, the company was paying around
$100,000 per year in unscheduled maintenance.

BY KAILEY HABERMANN
JWC ENVIRONMENTAL

T
he truck stops and
travel centers dotted
along North America’s
highways have long
been a place of refuge for
long-haul truck drivers
and families alike as they
travel the continent. Beyond
having the basics of fuel and
a bathroom, many locations
have accommodations to do
laundry, take a shower, have
a hot meal, use the business
center or even visit the on-site
urgent care clinic. Pilot Flying
J, the largest travel center
chain in North America, is
no exception. With more
than 750 locations across the United States, the Pilot Image 1. A manhole system that overcame frequent unscheduled
maintenance calls (Images courtesy of JWC Environmental)
Flying J facilities cater to the needs of thousands of
travelers every day.
Chopper Pump in Trouble
Eddie Slater, owner of Slater Plumbing & Mechanical, is
Pilot had a lift station that was continuously overrun with
most familiar with the Pilot facility on State Route 99 in
extremely tough debris—rags, mop strings, diapers and even
Bakersfield, California.
clothing. This was more that the station’s chopper pump was
Slater, whose company provides all kinds of commercial
designed to handle. For more than six years, Slater was on
and residential plumbing services, has supported the location
call 24 hours a day for seven days a week and making trips
for more than six years. If there was one thing that he could
regularly to unclog the pumps and ultimately prevent sewage
count on, it was that at least once a week he would be called
spills. Each unscheduled maintenance trip cost Pilot $500 to
out to the Bakersfield location to clean and unclog the
$2,000 depending on the severity of the clog, with a total bill
facility’s wastewater chopper pumps.
that eclipsed $100,000 some years.

March 2 0 1 8 | Pumps & S y stem s

Circle 108 on card or visit psfreeinfo.com.
34 SPECIAL SECTION CHOPPER & SHREDDER PUMPS
Image 2. The prefabricated fiberglass reinforced polyester (FRP) manhole system includes a grinder.
Image 3. Installation of the grinder solution
The grinder pump clogs were not just a massive expense
but they negatively affected the ongoing operations of the
truck stop. Slater’s response time was always speedy, but it
was impossible to arrive on-site instantly. On one busy day at
the travel center, the pumps clogged while sewage continued
into the lift station. Before normal pump operations could be
restored, sewage overflowed the wet well and flooded the Pilot
location and a connecting restaurant. The health department
forced both locations to close their doors until the cleaning
March 2 0 1 8 | Pumps & S y stem s
and sanitation was complete. The incident was topped off with
a hefty notice of violation (NOV) addressed to Pilot related to
the spill.
The Solution
Pilot Flying J was desperate to fi x this problem and needed to
find a solution fast. Pilot had worked with a sewage grinder
manufacturer at other locations across the United States for
sewage grinder solutions to protect pumps.
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36
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March 2 0 1 8 | Pumps & S y stem s
CHOPPER &
SPECIAL SECTION SHREDDER PUMPS
“This one was killing us—we were spending tons of money
to keep this lift station operating,” said Joey Cupp, senior
environmental manager for Pilot. The Bakersfield site was a
little more difficult than the typical grinder installation. There
was no room to install the grinder inside the wet well. Cupp
reached out to the grinder manufacturer for help.
Tom Smith, the grinder manufacturer’s employee supporting
Pilot, evaluated the situation and determined the best option
to fight the chopper pump clogs. The prefabricated fiberglass
reinforced polyester (FRP) manhole system includes a grinder,
Each unscheduled maintenance trip
cost Pilot $500 to $2,000 depending on
the severity of the clog, with a total bill
that eclipsed $100,000 some years.
guide rails, access ladder, inlet and outline piping for fast
connection and a manhole or hatch-type access lid. It was ideal
for installation in the pipeline upstream of the offending lift
stations and designed for rapid deployment.
Fast Fix Saves the Day
With the amount of money being spent weekly on
maintenance, any delays were costing Pilot hundreds if
not thousands of dollars. Expediting the unit was crucial.
The system was shipped and arrived within days ready for
installation. Slater and his crew were able to dig down to the
inlet pipe, cut the sewage line, drop the manhole into place and
make the connections. With the typical one day or less set up,
the manhole was installed and functioning.
Slater credits the sewage grinder for solving the massive
chopper pump clogs, downtime and expenses related to
clearing the flushed debris. Slater has not been back to the site
to unclog pumps since the grinder was installed.
“We are big fans of the grinders,” Slater said. “We have other
customers with similar problems and have purchased three
grinders since the Pilot installation.”
Kailey Habermann is marketing associate
at JWC Environmental. She may be reached
at 714-428-4661. For more information, visit
jwce.com.
 37

& U P G R A D ES
R E S T O R A T I O N b R ul e C
o m p li a n ce |
U n co m m
on Sh af t B r e a
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r a t e | EPA 316
H ydr a ul i c R e

The Aftermarket is an ever-growing component of the process industries. End

users need reverse engineering when a pump or a part is no longer available. New
regulations call for more creative ways of helping existing systems meet the required
operational rules. Complex system issues can cause leakage, breakage or out-and-out
system failure. Sometimes, just finding the right part can be a challenge. End users
turn to those aftermarket parts and services providers who can help. In the following
pages, we talk about some solutions, and we ask you tell us more. Please email your
Aftermarket experiences to pumpeditors@cahabamedia.com.
(Photo courtesy of Hydro Inc.)

p u m p s a n d s y s t e m s . c o m | M a rch 2018
38

AFTERMARKET

Engineering Analysis of a
Reactor Charge Pump Leads
to Full Restoration
A detailed study and hydraulic rerate improves operating conditions
for an ultra-low sulfur gasoline reactor charge pump.

BY GARY DYSON, HYDRO, INC

&THOMAS HESS, MONROE ENERGY

A
n aftermarket services provider was contacted by
a major oil refinery to rerate and upgrade a reactor
charge pump for a relocated processing unit. In its
previous installation, the pump had a history of
persistent high vane pass vibration despite several attempts
to modify the pump and support pedestals by the pump’s
original equipment manufacturer (OEM). Due to the reduced
feed rate to the unit at the new location, the pump required a
hydraulic rerate in addition to the need for reduced vibration.
By performing a complete, in-depth engineering study
of the original design, the aftermarket services provider
was able to perform a hydraulic rerate and improve pump
efficiency, dramatically reducing the vibration to acceptable
levels. The engineering analysis of the existing equipment
provided a road map to perform the necessary modifications.
The vane pass vibration was substantially reduced using a
newly designed impeller. Due to the lower vibration levels,
the end user can now expect a greatly increased mean time
between failure (MTBF) relative to the previous design.

Background
The reactor charge pump was purchased along with 10 other
pumps from a mothballed facility as part of a project to
build a new ultra-low sulphur gasoline unit to comply with
new Environmental Protection Agency (EPA) regulations.
The newly required duty point was roughly 60 percent of the
original rated flow, but the user required approximately the
same head. The pump was originally designed to operate at Image 1. The reactor charge pump in the field
1,372 feet of head and 2,135 gallons per minute (gpm) with (Images courtesy of Hydro, Inc.)

March 2 0 1 8 | Pumps & S y stem s

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40 COVER SERIES AFTERMARKET
Image 2. The end user observing the improvements to vane pass vibration using the new impeller.
Image 3. The duty point on the “H-Q” curve is where a centrifugal pump
operates its BEP. The flow rate is determined by the total head at the
respective pump speed.
the best efficiency point (BEP) at 1,285 feet and 2,700 gpm.
The newly required duty point was 1,378 feet and 1,442 gpm.
In the past, the pump had suffered from excessive
vibration. There had been repeated unsuccessful attempts
to reduce the vibration by changing the baseplate pump
support pedestals and modifying the impeller discharge
area. However, to eliminate the impeller vane pass vibration
problem and provide stable operation at the new operating
condition, the impeller geometry required changes, and the
number of vanes needed to be increased from four to five.
Pump casing geometry modifications were also required.
March 2 0 1 8 | Pumps & S y stem s
Image 4. Casing data: The radial-split casing was
also inspected dimensionally and laser scanned to
capture the required data for hydraulic analysis.
Both the casing and covers were digitized and
critical geometry was extracted for analysis.
Case scan data image created using ROMER Arm
technology.
Engineering Analysis
To achieve the key objectives of the project, a 3-D rotor model
was developed using dimensional data captured during the
reverse-engineering stage of the process. After the analysis
of this data, the aftermarket services provider gave specific
solutions and recommendations to improve both the impeller
and volute casing hydraulics.
The study was divided into two sections: hydraulic and
mechanical analysis. The hydraulic portion addressed subjects
such as suction specific speed, suction recirculation factor,
net positive suction head required (NPSHr) and impeller
Circle 117 on card or visit psfreeinfo.com.
42 COVER SERIES AFTERMARKET
Image 5. A rotor 3-D model was developed to verify radial loads
and review bearing characteristics and rotor lateral critical
speeds.
Image 6. Final impeller design
efficiency. The mechanical audit explored standard lateral
rotor dynamics checks including rotor-bearing system
modeling, undamped critical speed analysis, damped
unbalance response analysis and components design such as
pump shaft, wear rings and material upgrade opportunities.
Problems, Solutions & Challenges
In its original design, the pump was operating well below
the BEP and had high vibration, leading to failure. The
attempts to rectify the high vibration problems required that
the pumps be removed on several occasions within a short
time frame. According to the aftermarket service provider’s
analysis, the pump exhibited high vibration amplitudes at
vane pass frequency due to the inadequate impeller design.
The high head in a single impeller stage operating at two pole
March 2 0 1 8 | Pumps & S y stem s
Image 7. Test exceeded the original design expectations.
speeds suggested that the pump should have been specified as
a multi-stage pump rather than a single stage pump.
During the hydraulic rerate process, the aftermarket
services provider determined that rather than having a
straight through, V-cut vane discharge profi le, it would be
beneficial to design a new impeller using separated vanes
that were both staggered and raked. This solution solved the
problem of the vane pass vibration.
The new impeller geometry was too complex to
manufacture using traditional sandcasting methods,
even with modern 3-D printing technology. Due to time
constraints, investment casting was also not an option.
Instead, the aftermarket services provider opted to fabricate
the impeller using milled vane technology.
Conclusion
The reactor charge pumps were found to be significantly
oversized for the new application. The newly required duty
point was roughly 68 percent of flow of the old rated duty
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44 COVER SERIES AFTERMARKET

The first step of any engineering study is to take a full set of

Image 8. Vibration taken by the previous pump owner in 2006
at 1,260 gpm flow vs rerated pump 2017 at 1,270 gpm flow
point at equivalent discharge pressure. To further complicate
the issue, the pump exhibited the previously mentioned high
vibration with repeated unsuccessful attempts to correct it.
dimensional information. The aftermarket services provider
used a ROMER Absolute laser scanning arm to take a full 3-D
scan of the impeller and case, in combination with traditional
measurement techniques to ensure both completeness and
accuracy of the dimensional data.
This data was then transferred to a 3-D solid model and put
into an assembly along with the shaft and case covers. This
ensured that everything fit together properly and allowed for
all the necessary internal clearances.
The aftermarket company then compared the upgraded
parts with the old ones, which confirmed that the new
impeller required a larger envelope than the old. Proper
adjustments to the casing were made before fitting any
parts together.
The full rotor dynamic and hydraulic analysis provided
solutions to maximize performance and ensure rotor
stability. Based on the findings of the hydraulic analysis
of the impeller, the aftermarket company designed a new
impeller that would both produce the necessary fluid flow
characteristics and significantly reduce the destructive
vibration patterns.

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The aftermarket services provider opted to turn away from
the old design of an uninterrupted, straight-across vane
discharge profi le in favor of a staggered and raked vane profi le
with a center rib between the inboard and outboard sides of
the impeller.
The company also modified the case volute area profi le to
match the new hydraulics.
Using computer-aided manufacturing/computer numerical
control (CAM/CNC) machining techniques, the aftermarket
company produced the new impeller through the use of milled
vane technology.
Although costly, milled vane impellers can be produced
more quickly than their sand-cast counterparts and have the
added benefits of much tighter tolerances and a smoother
surface finish.
This generally results in lower turbulence and friction loss,
which can result in higher efficiency.
Using the new impeller, the pump was tested at the
aftermarket services provider’s performance test lab. It was
certified by the Hydraulic Institute, thus proving to have
exceeded the original design expectations with additional
head and a lower NPSHr. The impeller was trimmed in
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45
accordance with the test results and retested to within
satisfactory tolerances.
The end user received a certified pump test that met their
needs. The vane pass vibration was substantially reduced
using the new impeller design. Due to the lower vibration
levels, the end user can expect longer service life for these
critical pumps.
Thomas Hess works as a senior reliability engineer at
the Monroe Energy, LLC (a subsidiary of Delta Air Lines)
oil refinery in Trainer, Pennsylvania. He is responsible for
improving rotating equipment reliability, capital project
support and engineering standards development for
Monroe Energy.
Gary Dyson is managing director with Hydro
Global Engineering Services. He has a Ph.D.
from Cranfield University and 30 years of
experience in senior positions with many pump
industry manufacturers. His expertise includes
pump hydraulic performance, design and
reliability improvement.
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p u m p s a n d s y s t e m s . c o m | M a rch 2018
46 COVER SERIES
YEARS
AFTERMARKET
Pumps & Systems Looks
Back: Upgrading Utility &
Process Pumps
Improvements to make your equipment better than new.
BY KURT SCHUMANN
Editor’s Note: As Pumps & Systems celebrates our 25th
anniversary year, we continue our series of reprinted articles that
remain relevant today. This article is an abbreviated version of an
aftermarket story that appeared in our November 1993 issue. The
full piece can be found at pumpsandsystems.com. Schumann also
has an article in this issue on page 48.
U
pgrade (up + grade, v.): to raise the grade of;
to raise the quality of a manufactured product
(Webster’s Third New International Dictionary).
A pump upgrade (also called a revamp or
retrofit) involves changing the mechanical or hydraulic
design or the materials to solve a problem or increase reliable
run time. An upgrade is different than a repair; an upgrade
improves the design beyond the original.
Rerates are a type of hydraulic upgrade, usually involving
a change in pump head capacity. Repowering may involve
repairs and/or upgrades. Philosophically, repowering is
different from normal pump maintenance because the plant
being repowered has decided to spend capital monies to
extend the plant’s useful life.
Pump upgrade goals include:
• decreasing plant operations and maintenance expenses
• increasing mean time between failures (MTBF)
• increasing pump and plant availability and efficiency
• complying with the latest legislative mandates (such as
the Clean Air Act Amendments of 1990)
• minimizing the risk of fire or other safety hazards
• eliminating hazardous materials
To identify upgrade candidates, pump users should review
maintenance records to see which pumps were responsible
March 2 0 1 8 | Pumps & S y stem s
for a disproportionate share of expenses or cause safety
or reliability concerns. Work with the supplier to evaluate
upgrades available for your pump. Provide a maintenance
history so problem areas can be addressed.
The following are upgrade examples:
Mechanical design upgrades
• install a stiffer shaft/rotor to reduce vibration
• modify structural elements to remove natural frequencies
from the range of pump forcing frequencies (rotational
frequency, blade pass frequency, etc.)
• eliminate threads (a source of breakage) on pump shafts
• modify components to make assembly/disassembly easier
• convert mechanical seals to further restrict or eliminate
leakage
Hydraulic design upgrades
• redesign first stage impellers to reduce cavitation damage
• redesign impellers to lower vibration for part load/
peaking operation
• control “A” and “B” gaps to reduce pressure and vibration
• improve efficiency
• optimize blade number to reduce pressure and vibration
• increase pump head capacity to meet system requirements
Material upgrades
• eliminate asbestos, an environmental hazard
• install impellers made of cavitation-resistant materials
for longer life
• use hardened wear parts to increase MTBF
• eliminate leaded bronzes because of environmental
problems with lead

• improve product-lubricated bearing materials
• change materials for seawater use
The following are examples of upgrades to improve pump
operation.
Boiler Feed Pumps
Boiler feed pumps are at the heart of most power plants,
and economical plant operation depends on reliable pump
operation. Many pumps from the utility building boom of the
1950s-1970s had larger capacities and more horsepower than
previously supplied in order to meet increased plant size. As
pump energy levels increased, so did the failure rate.
Progress has been made through manufacturers’ efforts
to address first stage impeller design, materials and rotor
dynamics. As a result, reliability of high-energy feed pumps is
attainable. Common boiler feed pump upgrades include:
1. The thrust collar nut can be modified to reduce shaft
bending stresses and shaft fatigue failure.
2. The bearing housing can be modified to spring-load the
thrust bearing.
3. Several sealing options are available, depending on the
application. Floating seal rings, serrated bushings, or
mechanical seals are often recommended to minimize first
cost while maximizing reliability and thermal efficiency.
4. Non-asbestos spiral-wound gaskets replace original
asbestos gaskets. Pumps with copper or iron gaskets can
be modified to accept non-asbestos spiral wound gaskets.
5. Improved first-stage impeller inlet designs expand
the stable operating range to lower flow rates without
cavitation damage, vibration, or pressure pulsations.
6. Dry couplings eliminate the need for periodic lubrication
and the associated chance of failure.
7. Add instrumentation to monitor and protect pumps.
8. A shrouded diff usor eliminates breakage problems and
allows improved alignment.
9. Improved bearing designs are available, including “high
stability” designs to eliminate half frequency problems.
Circulating Water Pumps
Maintenance requirements vary greatly, depending on
whether the pumps are used in freshwater or seawater.
Typical problems requiring pump maintenance are excessive
vibration and premature bearing wear.
Circulating water pumps in seawater face additional
problems due to corrosion. Material selection process
must consider general corrosion, velocity effects, galvanic
compatibility, pitting resistance, manufacturability and cost.
Upgrades for circulating water pumps include:
1. An inner column stop on pullout style pumps to hold
down the pump element.
47
2. A fl anged inner column with rabbet fits replaces screwed
inner columns, resulting in better bearing alignment.
3. Bearing spiders provide stiffer bearing support.
4. Shroud metallurgy upgraded in high-velocity areas
eliminates erosion and corrosion damage.
5. Inlet bell modifications lower the required submergence
and reduce vortexing.
6. Modified impellers optimize cooling water flow, increase
plant output or save pumping horsepower.
7. Erosion in iron casing vanes can be repaired. Coatings can
be applied to extend casing life.
8. Keyed shaft coupling improves shaft alignment and
eliminates problems with removing threaded couplings.
9. Rabbet-fit drive couplings replace body-bound bolt
couplings and improve alignment repeatability.
Boiler Circulating Pumps
Boiler circulating pumps (BCPs) are in a particularly sever
duty, handling 600 F water at over 3,000 psig.
Many of the original pumps supplied in the 1950s and
1960s exhibited less-than-desirable life spans. In light of this,
an upgrade program was developed that:
• adds a graphite-impregnated bearing
• improves the primary sealing device
• incorporates other reliability “lesson learned”
API Process Pumps
Process pumps may handle hazardous materials, and as a
result seal leakage is critical. Industry standards (API 610 7th
Edition), as well as federal legislation like the Clean Air Act,
address mechanical seal reliability and pump maintenance.
There are upgrades available for process pumps to improve
seal reliability and reduce emissions, including:
• using a heavy-duty rotor (shaft and bearings)
• enlarging the stuffing box bore for better seal cooling
• using a heavy-duty cartridge seal
This article focused on specific pumps, but upgrades are
available for most models and sizes. Pump companies are
useful resources for aid in problem solving. They are usually
anxious to apply new technology and gain field experience
with new designs and materials. Most upgrade suppliers can
customize upgrades for individual users.
This bio appeared with the original 1993 article: Kurt
Schumann is Manager of Pump Upgrades for the engineered
Pump Group of the Ingersoll-Dresser Pump Company, located
in Phillipsburg, NJ. He has 18 years of experience in design
engineering and field service of utility and process pumps.
p u m p s a n d s y s t e m s . c o m | M a rch 2018
48 COVER SERIES AFTERMARKET

How to Update Circulating

Water Systems to Comply
with EPA 316b
A site visit and testing are critical to the process.

BY KURT SCHUMANN
PROPUMP SERVICES LLC

T
he Environmental Protection Agency’s (EPA) 316b
requires utilities to reduce condenser cooling water
velocity at intake screens to mitigate the impact on
aquatic life. For utilities, this affects primarily “once-
through” circulating water systems, or units without cooling
towers. For existing plants, there is considerable flexibility on
a local basis to support practical and cost-effective solutions
to strike a balance between environmental and plant
economic issues.
Compliance with EPA 316b can involve many solutions,
including:
• Modify circulating water pump design or operations.
o Throttling pumps (see Image 1)
o Running fewer pumps
o Rerating one or more pumps
• Incorporate variable speed drives (VSDs).
• Increase inlet screen area (see Image 2).
• Add a cooling tower.
• Combinations of the above solutions
Options should be evaluated for best fit based on 316b
compliance, first cost, ongoing costs, time to implement and
impact on unit capacity and heat rate.
As a cost-effective option, some plants have considered
throttling their circulating pumps as a means to lower
screen velocity. But simply reducing flow rate by throttling,
if achievable, results in other trade-offs. While throttling is
cost effective to try (and is reversible), it must be evaluated
for impact on unit heat rate and output. Using the pump
discharge valves or condenser inlet or outlet valves to
throttle also requires review of the valve design for throttling
ANALYSIS OF THE CIRCULATING
WATER SYSTEM
1. Visit the site and conduct a system walkdown.
Collect data, drawings, curves, etc. Discuss plant
goals and constraints (see Image 5).
2. Develop a test plan. Discuss testing plan with
site personnel.
3. Perform system testing. Collect flow and
pressures including pump discharge pressures,
condenser inlet and outlet pressures, motor
data. (There are many options for flow metering
to determine existing pump and system
performance. If possible, non-intrusive flow
metering is performed. If this is impractical,
there are alternate testing means to determine
system capacity.)
4. Perform an analysis of data and issue report
and conclusions.
5. Present options and cost/benefit analysis.
mode. These valves are usually butterfly isolation type and
not designed for continuous throttling. Additionally, the
circulating water pumps may not be candidates for long
term operation at the lower flow rates due to their particular
hydraulic design.

March 2 0 1 8 | Pumps & S y stem s

 49

Image 1. Typical circulating water pump installation (Images courtesy of ProPump)

Image 2. Existing traveling screens

Partial throttling (i.e. more modest

flow reduction, staying above the
recommended minimum flow rate)
may be more practical if combined with
other options, such as cascading pumps
Image 3. “Dip” the head-capacity curve for low head pumps
(idling one in the winter) or traveling
screen inlet area increase. Several
sites with older, idle units have been
studied. These idle units could allow designs using high specific speed and as a result, high specific speed
refurbishment and utilization of their impellers (similar to boat propellers). pumps may have higher recommended
existing intake structures to increase High specific speed pump designs often minimum flow rates, up to 65 to 85
screen area and lower intake velocities have a dip or instability in the head- percent of design capacity. (Hydraulic
without the major expense of new capacity curve at about half of full Institute suggests 80 percent for specific
screens or intake structures. capacity (see Image 3). This is an area speeds above 4,500.)
From a pump hydraulic design of hydraulic flow mismatch resulting There are other factors that affect
perspective, once-through systems are in increased vibration and noise. This the acceptable minimum flow, such as
high capacity, low head (low pressure) instability is generally to be avoided, impeller inlet velocity (tip speed), energy

p u m p s a n d s y s t e m s . c o m | M a rch 2018
50 COVER SERIES
AFTERMARKET

level, inlet design and materials of construction that also need

to be considered. In general, lower energy pumps will operate
acceptably at lower flow rates than higher energy pumps. One
measure of energy level is the impeller tip speed, which is the
velocity of the impeller inlet tip, typically expressed in feet per
second. The inlet tip speed is calculated as shown in Equation 1.

Impeller eye diameter (inches) x rpm

Inlet tip speed (ft/sec) =
229
Equation 1

Typical inlet tip speed design values for circulating water

pumps range from 50 to 85 feet per second (ft/sec), with the
higher tip speeds requiring higher minimum flow rates to avoid
damage. Any consideration of throttling for long periods needs
to evaluate the inlet tip speed as well as other key factors.
From involvement in various 316b system studies, some
generalizations can be made.

Circulating Water Pumps

Many older systems lack “design basis” documents, such as
pump curves, system resistance curves and hydraulic gradients.
These are important for analysis and future plant needs and can
be recreated as part of
the testing program if
missing. Most pumps
were not designed for
low flow operation
(some performance
curves do not even
provide low capacity
data, since it is not
recommended to run
Image 4. Wetted vibration transducers the pumps there).
provide vibration data below grade Many pump curves
are not completely
Circle 131 on card or visit psfreeinfo.com.

accurate due to worn

pump components,
inaccurate original
curve (often
the dip area is
misrepresented),
or use of incorrect
replacement hydraulic
components.
Circulating pumps
Image 5. Site walkdown and data used in parallel (most
collection
cases) must maintain

March 2 0 1 8 | Pumps & S y stem s

 51

the same rpm. If the system uses VSDs, they must be used on
all pumps in a common unit and operate at nominally the
same speed.

Cooling Water System

Condensers are often running inefficiently and lack
instrumentation to monitor and trend performance including
cleanliness (increased pressure drop due to tube fouling), liquid
level in water boxes and presence of vacuum leaks.
Once-through systems have system resistance curves where
the head varies with the square of capacity. This makes them a
good fit for variable speed drives, since the pump head-capacity
varies similarly—the pump remains at good efficiency and
above minimum flow at all speeds (see Image 4). Reduced pump
speed is usually obtained via variable frequency input to the
motor but can also be obtained with a fluid or magnetic drive
or a multi-speed motor.
Some units have low capacity factors, and may be cost
constrained from major capital investments. The choice is to
keep the costs modest or shut down the unit.

Instrumentation
Flow metering can be difficult on once-through systems due to
buried pipe, pipe materials (concrete or concrete lined) and lack
of accessibility. Several intrusive and non-intrusive methods
can be employed to provide adequate flow metering results.
Circulating pump systems have minimal instrumentation,
often lacking basis data such as:
• discharge pressure
• intake water level
• vibration monitoring
• motor amps
• motor thrust bearing temperature

Vibration data below grade (wetted transducers) should

be considered to improve the ability to monitor circulating
water pump health and provide early indications of distress
(see Image 6). Plants need a reliable method of estimating and
reporting water usage to the regulatory agencies. This can be
Circle 133 on card or visit psfreeinfo.com.

determined by direct measurement of velocity or calculated

from other data. Due to the potential large expenditures for
some of the possible options, it is beneficial to start with
a system analysis to evaluate the original design, current
operations and options for desired performance.
Analysis of the circulating water system involves multiple
disciplines and includes the pumps, motors, condenser, valves,
piping and ancillaries. An investigative process that has been
successfully used at various locations includes the five key
steps listed on page 48.
In conclusion, there are many options for compliance
with 316b. Plants are different, and each one has a different

p u m p s a n d s y s t e m s . c o m | M a rch 2018
52 COVER SERIES AFTERMARKET

set of constraints and cost/

benefit situations. The lowest
cost solution is typically to
use existing hardware and
modify operations to achieve
compliance. If inadequate,
various hardware changes can
be made to pumps, motors
(including VSDs), piping
system, and/or intake screens
to achieve compliance at an
acceptable cost to the plant.

Kurt Schumann is president of

ProPump Services LLC. He may
be reached at kschumann@
propumpservices.com or
Image 6. Effect of speed variation on pump head-capacity showing good match with
610-868-8425. For more
system resistance curve information, visit
propumpservices.com.

Circle 121 on card or visit psfreeinfo.com.

March 2 0 1 8 | Pumps & S y stem s

 AFTERMARKET COVER SERIES 53

What Causes Shaft

Breaks in Positive
Displacement Gear Pumps?
This plant solved the mystery of sudden, frequent pump failures.

BY STEPHEN BELL
CAROTEK

A
fter years of using large internal gear pumps for
asphalt flux, a roofing materials manufacturer
suffered multiple shaft breaks in a series of pumps.
These shaft breaks were uncommon in past usage
and were brought to the attention of the pump supplier. The
pumps typically operate at 100 gallons per minute (gpm) and
less than 100 pounds per square inch (psi) discharge pressure.
The system uses a hot-oil heating loop to maintain the asphalt
flux at a proprietary high temperature to reduce the viscosity
of the product enough to allow smooth flow and reduce pipe
wall buildup of solid asphalt flux.
The pumps are operated by 30 horsepower (hp), 1,750
rotations per minute (rpm) motors and a gearbox that reduces
the pump speed to 100 rpm for product flows of 100 gpm.
The pumps are used to transfer asphalt flux from tanks in a
still yard to the final application of the asphalt flux on the
process line.
The same pumps have been in use for more than 20 years
in this facility. Normally the life expectancy of these pumps
was much longer in this service, and this mode of failure
was never observed in the past. It is important to note that
the facility uses two versions of the same size pump for two
different applications. One is considered a soft pump for
asphalt flux applications and the other is considered a hard
version for fi lled asphalt applications. The hard pump has
a hardened steel rotor and shaft to reduce wear from the
abrasives in fi lled asphalt.
When the shaft break issue was brought to the attention
of the pump supplier, the quantity of failed pumps over Image 1. Chart sample of captured process data (Courtesy of
approximately 12 months was six pumps. There were 18 Carotek, Inc.)
pumps total in this application. In years past, the quantity of

p u m p s a n d s y s t e m s . c o m | M a rch 2018
54 COVER SERIES AFTERMARKET

failures were
analyzed and the
following results
were determined
and addressed as
indicated.

Analysis
The pump supplier
and manufacturer
carefully analyzed
Image 3. Rotor and shaft bend and deflection (Courtesy of the pumps
Image 2. Shaft turned within the rotor and sheared Viking Pump) with broken or
set screws (Courtesy of Certainteed) turned shafts.
Dimensional
pumps failing in the same period was one on average. Some of checks and metallurgical analysis of the shaft and set
the pumps had broken shafts that were sheared at the shaft/ screws were conducted. Both were found to be within the
rotor connection while some showed the shaft had turned manufacturer specifications. Once the pumps were burned
within the rotor, shearing the set screws meant to keep the out to remove residual hardened asphalt, abnormal wear
rotor and shaft intact. patterns in the pumps showed excessive discharge pressure
The sheared shafts were on hard pumps and the shafts had deflected the shaft and forced the rotor into the suction
that were turned within the rotor were the soft pumps. The side of the pump casing (see Images 2 and 3).

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March 2 0 1 8 | Pumps & S y stem s

 55

There were signs of wear on the suction side of the casing

where the rotor was pushed into the casing wall. There were
also signs of wear on the suction side of the head plate where
the rotor deflected into the head. Other signs of wear in the
bushing, idler and crescent also indicated overpressure and
subsequent shaft bending and deflection. When the rotor
pushed against the casing and head, excessive torque caused
the shaft to break or turn inside of the rotor shearing the
set screws.
The manufacturer analysis read that “subsequent
overpressure resulted in shaft bending, which in turn
resulted in casing wear, head wear and eventual rotor/shaft
assembly breakage.” In some cases, the shaft turned within
the rotor, shearing the set screws and disengaging the rotor
from the shaft. This analysis led to design changes in the
pumps by the manufacturer and an analysis of operating
procedures of the process within the facility.
The pump manufacturer’s published maximum discharge
pressure is 150 psi in this pump partially due to the shaft size
and subsequent length-to-diameter (L/D) shaft deflection
ratios. Any excess of 150 psi could cause shaft bending and Image 4. Wear patterns in internal gear pumps (Courtesy of
Viking Pump)
deflection as was seen in the failures at this facility.

Recognized
Excellence.
This month, we would like to thank our master
distributor, PM Supply, for their continued support and
The PM Supply, Inc. team
relationship with us. PM Supply is located in Ebensburg,
Contact Us Pennsylvania, and has earned the reputation of being
PM Supply, Inc.
pmsupplyinc@gmail.com
the area’s leading pump distributor and repair team.
814-472-4430 They partnered with us in 2015, and it has been
HCP Pumps America a mutually beneficial parternship. HCP Pumps America
sales@hcppumpofsamerica.com
251-943-8080 has provided high-quality pumps at competitive prices,
and PM Supply has become our Northeast master
distributor. They continue to go above and beyond—
Our AFC Series cutter pumps & impeller not only for us—but for their customers as well.
with tungsten carbide tips

Circle 124 on card or visit psfreeinfo.com.

p u m p s a n d s y s t e m s . c o m | M a rch 2018
56 COVER SERIES AFTERMARKET

Standard operating procedures at the facility compensated Resolution

for the 150 psi maximum allowable discharge pressure, and
measures had been taken to see that the temperature and
viscosity of the asphalt flux was maintained such that the
discharge pressures would not exceed this limit. In fact,
pressures rarely exceeded 100 psi, as was indicated in process
information later gathered by the facility maintenance team.
However, there were considerations of whether energy
savings initiatives may have caused excessive discharge
pressure beyond the maximum allowable discharge pressure
of the pump. During downtime at the facility, such as
weekend shutdowns, temperatures maintained on the asphalt
flux via hot-oil heating loops were reduced to save energy.
After investigating, it was determined that the start-up time
to bring the asphalt back to acceptable temperatures and
viscosities may not have been increased to compensate for
the lower weekend downtime temperature. Therefore, the
asphalt may have been too cold and viscous at start-up after
the weekend shutdown and discharge pressure on the pump
exceeded the 150 psi limitation. There were no records of
temperatures and pressures during these start-ups or pump
failures, so this hypothesis was assumed.
Once these factors were considered, the manufacturer
took measures to address the pump shaft deflection, and
the facility maintenance team focused on addressing the
standard operating procedures. Each group took action to
resolve further shaft failures.
The pump manufacturer made a design change in the
pump to incorporate a larger shaft. The shaft diameter was
increased by 40 percent.
This thicker shaft helped to reduce the shaft deflection by
66 percent, thus reducing the potential for premature wear
and rotor/shaft assembly failure. The larger shaft increased
the L/D shaft deflection ratio and increased the maximum
allowable discharge pressure to 200 psi.
This design change later became the standard for this size
pump for all future builds by the manufacturer. There was
no change in shaft diameter at the drive end of the pump, so
existing power transmission equipment such as sheaves and
couplings will still apply to the pumps.
The pump supplier placed process monitoring equipment on
the asphalt flux pumps to measure process loop temperature,
discharge pressure and motor amperage. Recordings were

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March 2 0 1 8 | Pumps & S y stem s


taken electronically every two seconds as well as visually
monitored three times per day by the facilities maintenance
team for three months.
The facilities maintenance team reviewed the standard
operating procedures specifically related to shut down and
start-up procedures regarding the asphalt flux temperature
loop. Changes were initiated to prevent the occurrence of
“cold” start-up conditions.
Conclusion
By determining the pumps were over-pressurized through
the analysis of the wear patterns in the pump, the team was
able to focus its attention on why the high pressures were
occurring and what could be done to prevent future shaft
breaks and unwanted downtime.
The facilities management team diligently looked at the
product temperatures and viscosities during run conditions,
shutdown times and start-up times. They determined that
changes in operating procedures could be adjusted to prevent
a cold start-up condition that could increase viscosities in
the asphalt flux and cause high-pressure spikes. The pump
manufacturer agreed that a larger shaft in this size pump
Circle 130 on card or visit psfreeinfo.com.
57
was achievable and would allow for less shaft deflection and
higher pressure capabilities. That design is now the standard
product for the manufacturer.
The team effort of the facilities maintenance team, the
pump manufacturer and the pump supplier resulted in
reductions of pump failures due to shaft breaks by analyzing
the root cause of the breaks.
Initiatives were taken by all parties to prevent similar
failures in the future. Since the standardization of the
larger pump shaft by the manufacturer and the attention to
temperature loop conditions by the facilities maintenance
team took place, failures due to shaft breaks were completely
eliminated in these applications. Since 2012, there have
been no shaft breaks causing unnecessary downtime in
this facility.
Stephen Bell is vice president, mechanical
products at Carotek. He may be reached at
stephen.bell@carotek.com or 704-844-1100. For
more information, visit carotek.com.
p u m p s a n d s y s t e m s . c o m | M a rch 2018
58 SPECIAL REPORT COUPLINGS

COUPLINGS
How to Choose the Proper Coupling for Your Pump
By Brent Harrison
MAX Industrial Solutions

In the coupling industry, the STAMP acronym is used on a daily basis to

determine the best hose or coupling for an application.

S
SIZE:
What is the minimum outside diameter required for the pump to operate
efficiently? Properly sized couplings prevent pump cavitation and increased
temperatures under high workloads.

T TEMPERATURE:
What is the maximum operating temperature? Coupling materials can
degrade under extreme pressures. Always make sure to pair the right
coupling to the maximum operating temperature of the system.

A APPLICATION:
What application will the coupling will be installed in? Will the
coupling system need to be detachable? Is there a high level of
vibration or pressure impulse that may cause the coupling to
wear out prematurely?

M MEDIA:
What type of fluid will the coupling be exposed to? Certain volatile chemicals can cause complete
failure of a coupling system in a very short amount of time. Always make sure to verify the media
being transferred with the manufacturer’s chemical compatibility chart.

P
PRESSURE:
What is the maximum pressure of the system? While most
industrial coupling systems operate in a low pressure
environment, pressure is still very important. Always
verify what the maximum system operating pressure
is before selecting a coupling.

March 2 0 1 8 | Pumps & S y stem s


The Rise of ICS Malware
What can these programs do, and what are the capabilities you
need to protect your system?
BY BARAK PERELMAN
INDEGY
I
n December, a new malware variant specifically designed
to attack industrial safety systems was identified as being
responsible for causing an operational outage at a critical
infrastructure facility in the Middle East.
The malware, dubbed TRITON, or TRISIS, targets Triconex
safety instrumented system (SIS) controllers. It replaces the
logic of SIS controllers, an action which can prevent the safety
system from functioning correctly and result in physical
consequences. TRITON represents the growing escalation
of cyber threats being developed to target industrial control
systems (ICS).
In addition to TRITON, previous variants of industrial
malware have focused on gaining access to programmable
logic controllers (PLCs), not SIS controllers specifically. Since
PLCs are used to operate manufacturing processes, water
and wastewater treatment facilities, energy distribution
and more, ICS malware places facilities, personnel and the
environment at risk.
For example, malware could reprogram these devices to
shut valves, modify formulations for pharmaceutical, food
and beverage products, display false readings, etc.
To date, five ICS-specific malware variants have been
discovered.
1 Stuxnet (2010): This was first malware to specifically
target supervisory control and data acquisition (SCADA)
systems and programmable logic controllers (PLCs). It
was responsible for causing substantial damage to Iran’s
nuclear program.
2 Havex (2013): A remote access Trojan (RAT) was used
as part of a widespread espionage campaign targeting
ICS environments across numerous industries. It scanned
infected systems to locate SCADA or ICS devices on the
network and sent data back to the attackers. Havex was an
intelligence-collection tool used for espionage and not for the
disruption or destruction of industrial systems.
59
SPECIAL REPORT
CYBERSECURITY
PROTECTING ICS FROM CYBER THREATS
As the explanation in this article demonstrates, a
successful cyber attack is a multi-stage process.
To detect ICS security threats, the following
capabilities are required:
• Detecting remote connections, network scanning,
unauthorized system access and attempts to read
controller information
• Monitoring communications between industrial
systems on the network and to external systems
• Identifying any changes to controller logic,
configuration and state
3
BlackEnergy 2 (2014): This was modified from an
existing malware variant called BlackEnergy to target
human-machine interface (HMI) software from a handful of
vendors, including General Electric, Advantech/Broadwin and
Siemens. It was used in the cyber attack that took down the
Ukrainian power grid in December 2015.
4
Crash Override/Industroyer (2016): This is the
first known malware designed to attack electric grid
systems and was used in the December 2016 hack on a
transmission substation in the Ukraine. It is new and far
more advanced than the general-purpose tools used to attack
Ukraine’s power grid in 2015. What makes Crash Override
so sophisticated is its ability to use the same protocols that
individual electric grid systems rely on to communicate
with one another, sometimes called control-plane protocols.
Stuxnet and Triton also access these native protocols.
5
Triton (2017): Since most ICS environments suffer
from lack of visibility, it is difficult for organizations to
identify malicious activities once an adversary gains access to
the operational network. Fortunately, new technologies can
detect and respond to threats like the TRITON malware in
real time. Following is an analysis of an ICS malware attack.
p u m p s a n d s y s t e m s . c o m | M a rch 2018
60 SPECIAL REPORT CYBERSECURITY
During network and system infi ltration, the adversary gains a
foothold in the network and starts reconnaissance activity:
• A remote connection may be used to infi ltrate the
industrial network.
• Once inside the network, the adversary can scan the
network to identify ICS devices.
• Since ICS networks do not use authentication or
encryption, an adversary can access any system—
including operator or engineering workstations, HMIs,
Windows servers or controllers—to identify assets to
target in the attack.
Next, data exfi ltration involves extracting information
gathered via reconnaissance to an off-site location. An
adversary could either pass the information internally from
different systems to a single location where it can be extracted
or open a connection to an external system for exfi ltration.
In the next step, malware is installed on a workstation with
access to the targeted ICS system(s) using knowledge gathered
during network and system infi ltration and data exfi ltration.
This can be accomplished via the network or by using an
infected USB drive.
March 2 0 1 8 | Pumps & S y stem s
In the final stage, the malware replaces existing logic and
uploads new ladder logic to the controller. Since this logic
determines how automated processes are executed, changing
or replacing it with malicious payloads can result a wide
range of operational disruptions and even physical damage to
systems, the environment and humans.
See the box on page 59 for steps to take to prevent a
cyber attack on an ICS. This level of visibility can provide
real-time alerts with detailed information. Meanwhile, a
comprehensive audit trail can enable security professionals
to accurately identify the source of an attack, the commands
used and devices impacted. This intelligence is critical for
early detection of threats as well as determining how to
respond and shorten mitigation and recovery times.
Barak Perelman is CEO of Indegy, an industrial
cybersecurity firm. Before founding Indegy, he led
several multimillion dollar cybersecurity projects
at the Israel Defense Forces (IDF). A graduate of
the Talpiot military academy, Perelman has over
15 years of hands-on experience in cybersecurity
and protection of critical infrastructures.

Debunking the
Millennial Myth
Understand younger employees,
and learn how to make the
workplace work with them.
BY ANDREW YEGHNAZAR
BLACOH INDUSTRIES
W
hat is it about “kids” these days? They come
to us flush with degrees and limited work
experience, looking for a fulfi lling job. They
are confident, eager and anxious to make a
difference. Yet even before you can say “welcome aboard,”
they are already asking for flextime and a promotion. They
want to “friend” their boss on Facebook and prefer texting
over emails. But what they are really looking for is a coach
or a mentor—not a boss. So what is real, and what is a
misconception and a stereotype?
It seems like they are looking for a shortcut to climb the
corporate ladder, yet they want a dynamic and evolving
culture, yearning to be on the team that could put a man on
Mars. They are easily bored and will relentlessly seek the next
challenge, whether it is in the same company or elsewhere.
I’m talking about the largest living generation in America:
Gen-Y, dubbed the millennials, born between 1982 and the
year 2000. However, if you look around, these people are not
just kids anymore. Today, the median age of a millennial is 27,
with a substantial percentage extending to early thirties. And
they work on your team.
Here’s my point. Though your organization may still be
selling solid products developed at least 20 years ago using
30-year-old traditional distribution and marketing channels,
are we missing the mark? The up-and-coming workforce in
our industry today has undergone tremendous change in
the past few years. We have seen a lot of change with process
innovation, new technologies, globalization, acquisitions
and new emerging markets. However, the glaring elephant in
the room, largely unrecognized, is the transformation of the
workforce into an increasing millennial attitude and culture.
Just as we have successfully adapted to a modern industry, as
business leaders, we must adapt to a modern workforce.
WORKFORCE SPECIAL REPORT 61
Let me be clear. I’m not talking about reworking the
“human” resources mold you’ve been using since the
Reagan White House. I’m saying you quite possibly need to
completely retool your approach and mindset. When it comes
to millennials, ignore the stereotypes, and take a closer look
at their motivations.
Motivations
Are millennials truly a unique generation who think so
differently from the rest of us? Yes and no. They are unique
in that they are better educated, better connected and more
socially conscious on a global scale. Raised in a culture of
search engines, app updates, the cloud and streaming live
data, they are accustomed to rapid innovation, instant
gratification and unlimited access to information—any time
and everywhere. Boredom in a world (or a work environment)
without change and constant feedback is nonsensical to a
true millennial. And yet, they came of age in the midst of
economic recession and high unemployment rates. When
they leave college, many are grateful to have a job so they can
begin paying off their generation’s estimated $1.2 trillion
dollars in student loan debt.
For all of their attributes and talents, millennials are
somewhat misunderstood in the workplace. Their desire
is to change the world. They have been given a consistent
message on how great they are, how they can be anything
they want to be and are encouraged to be dreamers and
impact the world. However, this lofty attitude towards life
can easily set them up for high expectations when they enter
the workforce only to be disillusioned when the theoretical
world of academia intersects with the practical world of
employment. Having received limited criticism combined
with a boosted confidence, it is easy to perceive them as
p u m p s a n d s y s t e m s . c o m | M a rch 2018
62 SPECIAL REPORT WORKFORCE
impatient or arrogant. Their less formal and
more familiar communication style may come off
as disrespectful. They are accustomed to doing
things on the go and multitasking, so they are
greatly confused for the need to sit in a cubicle
eight hours a day in order to be productive.
More than any generation before them, the
millennials’ primary priority in a job is the
culture. Once you understand that, you are well
on your way to more effective inter-generational
communication. And another major area of
misunderstanding is that of loyalty. Millennials
can and will be loyal to you but need to feel that
you are loyal to them and committed to their
continued development and personal growth.
And for that, the leadership of the organization
is where they look.
Millennial Behaviors
So what does it mean when a staff millennial
waltzes into the president’s office just to chat? Is
it a sense of entitlement, or are they looking for
affirmation? Understanding the differences here
is key to ensuring this generation is able to reach
their full potential and, just as importantly, to
do so within your organization and not with
your competition. They are smart and are able
to identify if the organization’s coaches and
mentors, aka “bosses” actually walk the talk.
The entrepreneurial spirit of millennials
cannot be underestimated, but they are also
far less motivated by money than you might
think. Millennials often want to have a positive
impact on the world around them. They want
their work to have purpose and meaning.
They are big on social justice in every aspect
of their life, including work. They need to
be challenged and know they are making a
meaningful contribution.
Most of all, they want to work for an
organization that shares their values. It’s not
that their ideals and aspirations themselves
are so different from other generations. The
difference is that millennials have certain
expectations and are willing to leave if those
expectations are not met, even if that means
taking a pay cut. And I am pretty sure many of
you reading this article have experienced this
first-hand already.
Millennials favor leading edge, innovative
organizations and, like any young generation,
they want to be associated with leaders who are
March 2 0 1 8 | Pumps & S y stem s
EDITOR’S NOTE: This year, Pumps
& Systems is working to expand
our coverage of workforce issues
in our industries. This began
in our January 2018 issue with
the article “Teaching Moments.”
Below is a reader response to
that article on the importance of
operator training.
You speak of training for
engineering types and that is
good. You are forgetting about
the operators of plant equipment.
The best, most perfect equipment
overhauls can be destroyed in
minutes by an operator that has not
been taught how to operate their
equipment or what is important.
Most plant operators do
not even know how a pump
produces pressure, what a pump
curve is trying to tell them, or
how a mechanical seal works.
Without these, there can be no
troubleshooting.
Julien Le Bleu
Sage Technologies LLC
We also got some excellent
insight from other industry
professionals on how their
companies are dealing with
training and recruiting.
With unemployment at a low level,
we are finding it more and more
difficult to find new people with the
skill set to work in our factories.
What we have done to alleviate this
problem is develop a learning cell to
run our machines. New employees
work as apprentices for six months
when they are rotated through
various machines every six weeks.
We also work closely with local high
schools where we have open houses
throughout the year and the area
vocational schools to give tours and
find the top prospects. We have been
fortunate in filling professional
positions such as engineering,
sales and marketing staff. Even
though there appears to be fewer
candidates, the open positions are
being filled.
Kevin Jagielski
Director, Sales and Marketing,
Graco, Inc.
While these concerns affect all
manufacturing, we are finding ways
to attract the younger generations
to our company. One example is
something we did during the Society
for Maintenance and Reliability
Professionals (SMRP) this year in
Kansas City. We sponsored four
students from a local technical
college. They attended the SMRP
conference and stopped by our booth
to learn more about Fluke and
talked to some of our engineers. This
was a great opportunity to open the
door to four young men who may
otherwise not know who we are.
Finding these chances to introduce
ourselves and our benefits will be
something that we continue to do
moving forward, and we encourage
our colleagues in the industry to do
the same.
As a technology provider,
we are focused on streamlining
maintenance and reliability tasks.
As the workforce ages and youth
replaces, technology will become
a tool in the toolbox, rather than
an optional method. Millennials
are highly accepting of technology.
In fact, they demand it. Utilizing
technology in our field becomes an
attractive draw to our industry.
Kevin Clark, Director, Global
Service and Alliances, Fluke Accelix,
Fluke Corporation
 63

shaping the future of their industry. They perform best in a

collaborative environment, and yet they want recognition for
their individual contributions. They need to know their work is PUMP MOTOR
valued and that they’re not just another cog in the wheel. They
thrive on discovering the quickest and most efficient ways of
doing things. BEARING
They are perplexed and frustrated when they’re told to do
something simply because it’s always been done that way.
They thrive in a culture with a certain level of autonomy and
PROTECTION
cringe when micro-managed. Companies that truly value their • Reduce downtime
people by empowering their hires to take the lead, while bosses • Save money
convert to more of a coaching/mentoring role, are far more • Easy installation
• Superior
likely to attract and retain millennials. performance
Millennials value a flexible work environment with greater
access to leadership. This can be difficult for traditional
organizations to accommodate. However, understand it’s You can extend the life of your motors
quickly becoming the new normal. Millennials, more than and prevent costly damage to bearings!
earlier generations, strive for a healthier work/life balance. As
a group, they’ve been characterized as lazy, but research shows
they spend just as much time working and actually take less
time off compared to their older counterparts. They tend to
seek out leadership, but it’s not necessarily about getting a pat 1-800-962-4851 | helwigcarbon.com
on the back. They expect leaders will share their knowledge,
talk strategy and give feedback not only on their performance Circle 148 on card or visit psfreeinfo.com.
but also, their ideas.

Advice for Companies

My goal for this article was to share some key insights on the
characteristics of a millennial employee, avoiding traditional
misconceptions and embracing a new normal. To lead a
new generation workforce, it is critical we understand and
appreciate how millennials are wired, in order to maximize
their productivity and contributions to our businesses. It’s
not that our values are so divergent or that we need to change
our corporate culture to suit a new generation. It means being
effective in communicating ideals and adapting to changes in
the workplace, so that our people, our most valuable asset, have
every chance for success—which in turn will only positively
impact our business.
In my organization, we know we are not perfect, but this is
what we are attempting to do. Are we there yet? No. But, that is
where we are definitely headed.
Ours is an industry rich in seasoned experts and ripe with
young talent. We are and always have been multi-generational.
However, if you are still perplexed by this new generation of
millennials, perhaps the answer is to surround yourself with
more millennials and they will give you straight talk and guide
you. The question is, will you be willing to listen to them?

Andrew Yeghnazar is president of BLACOH Industries.

He may be reached at ayeghnazar@blacoh.com. For more
information, visit blacoh.com.
Circle 149 on card or visit psfreeinfo.com.

p u m p s a n d s y s t e m s . c o m | M a rch 2018
64 MAINTENANCE MINDERS

Maintenance Strategies for

Efficient Installed Assets
The IIoT offers affordable options for personnel charged with maintaining equipment health.

By Frederic Baudart, CMRP

Fluke Accelix

T
he Department of Energy’s pump
and motor efficiency rules have
directly affected new motors
and pumps being manufactured and
sold in the U.S. But what about the
efficient operation of existing, installed
equipment—assets that must function
efficiently and reliably as designed for
the system?
Equipment that is not maintained
(not properly lubricated, runs above
recommended temperature ranges, or
is misaligned or loose) will not operate
efficiently. How can maintenance teams
ensure that they maintain assets and
keep them functioning properly? One
solution is the Industrial Internet of
Things (IIoT).
The term IIoT is everywhere, but—
until recently—this technology has Image 1. A thermal imager provides information about hot and cold spots more regularly,
averting downtime and other problems. (Images courtesy of Fluke Accelix)
not been used to enhance and improve
maintenance activities. The IIoT has
typically been discussed as a solution Some examples of these recent adoption and today, implementation is
for industrial processes and operations technology options are connected easier than ever.
rather than for maintenance and handheld tools, enterprise asset Information technology (IT)
reliability. management (EAM)/computerized departments are becoming more
Part of the reason for this is that the maintenance management software accepting of cloud-based technologies.
price point to leverage the technology for (CMMS) systems, wireless sensors and They do not have to worry about
maintenance, particularly on noncritical software for automated meter reading software updates because, with cloud-
assets, has been high. and data integration. based technologies, these are carried
Today, however, because of new out automatically and in real time. This
IIoT offerings, the technology is more Cloud-Based EAM or CMMS equates to much less system downtime
affordable. If end users are not using the IIoT for because of software maintenance.
As a result, it is being applied work management and asset hierarchy Ultimately, an EAM or a CMMS
in flexible ways and can be a cost- setup (or at least considering it), they should have the ability to integrate with
effective resource for plant managers, will be required to move to this method machine data to provide actionable,
maintenance managers, reliability in the future. Maintenance and event-driven activities. In addition, the
engineers and maintenance technicians. reliability teams cannot wait for system should:

March 2 0 1 8 | Pumps & S y stem s

 65

• help maintenance personnel steps that many maintenance teams Your Best Value
must take as they begin their own
in Progressive
gather more accurate and complete
failure data reliability journey.
• provide for automated work
execution processes
The addition of wireless sensors can be
a first step from preventive maintenance Cavity Pumps
• track maintenance costs to allow for to predictive or condition-based
smarter budgeting decisions strategies by taking measurements that
• easily plan and schedule work are sent to the cloud. Two types that
• designate critical and/or capital can provide early warning of imminent
spare parts, track warranty problems are thermal imaging and
information, provide processes vibration sensors.
for equipment refurbishment
and restoration Thermal Imaging Sensors
• track and measure important key Infrared imaging allows personnel to
performance indicators (KPIs) such view high-level temperature data on
as machine downtime (or rather an asset. No matter the industry or
uptime), labor performance, wrench facility, faster response time to sudden
time, failure and Pareto data mishaps avoids catastrophic failure and
• ability to curtails damage
place data costs. With
literally thermal
within monitoring
reach of the Maintenance and sensors,
technician reliability teams maintenance
personnel can
These features cannot wait for check for hot and
not only help adoption and today, cold spots more
maintain assets regularly, averting
for efficient implementation is downtime and
operation, easier than ever. other problems
they also allow that could be
for efficient created by delay.
personnel work Temperature
assignments, thresholds can
sending technicians to the correct also be determined and parameters
equipment to carry out the right tasks. set up in the cloud-based software to Celebrating over 33 years
send an alert to any connected device if
Call or Email:
Connected Tools & Sensors thresholds are exceeded.
Maintenance systems are not an all or Some common problems that can 920-869-4800
sales@summitpump.com
Circle 146 on card or visit psfreeinfo.com.

nothing implementation. Pieces and be helped with the use of thermal

parts of a system may be added to the
technology lineup at different times.
Some measurements may be gathered
on preventive routes with handheld
devices. Other measurements can be
taken by wireless sensors and still
others by tools already installed on
the asset.
The ability to aggregate lots of data
from different measurement devices
is instrumental to the often small
monitoring are:
• Automated data collection: Many
maintenance managers in mid-
sized facilities with smaller teams
find performing regular equipment
check-ups with a thermal imager
difficult, so they often outsource TM
this function to consultants. This PUMP, Inc
tool is so simple to use that team
members can begin taking routine www.SUMMITPUMP.com
thermal images without third-party
BASED IN GREEN BAY, WI

p u m p s a n d s y s t e m s . c o m | M a rch 2018
66 MAINTENANCE MINDERS
Image 2. Thermal imaging sensors offer automated data collection that can
help overcome a reactive mindset and poor response time.
intervention. Managers can replace
some thermal inspection route-
based maintenance with automated
sequential images.
• Reactive mindset: Because many
facilities house seemingly countless
assets from rotating equipment to
small transformers, chasing problems
as they surface strains even the most
capable maintenance teams.
• Poor response time: If personnel is
spread thin and professionals are
Image 4. An EAM or a CMMS should have the ability to integrate with machine data to provide
actionable, event-driven activities.
March 2 0 1 8 | Pumps & S y stem s
Image 3. Vibration screening alerts personnel of many problems with
rotating equipment.
constantly hustling to handle the
latest equipment failure, response
time can suffer.
Thermal monitoring with infrared
sensors aims to alleviate these all-too-
common headaches.
The sensors inspect equipment,
regardless of the time of day or night,
for more efficient use of personnel
and to maintain the efficient operation
of equipment.
Vibration Screening
Vibration screening can provide early
warning of many problems with
rotating equipment including pumps,
compressors, turbines, motors, fans
and blowers. These faults may include
misalignment, imbalance, looseness
and bearing failure. Some abilities of
vibration sensors are:
• Reduce downtime. Avoid unexpected
downtime and associated expense of
repairs or replacement.
• Predict equipment failure. Notice
vibration abnormalities sooner, and
fi x problems at an earlier stage.
• Make data-driven decisions. Collect
historical equipment data and capture
recurring wear patterns to anticipate
trends.
• Minimize costs. A cost-effective
solution for capturing all
measurement-related data in a single
system.
• Avoid hiring vibration specialists.
The vibration sensor is easy to install
on virtually any machine and runs
on battery power with a three-year
life span.
• Access hard-to-reach monitoring
points. Screen vibrations from
hard-to-access measuring points of
critical equipment.
 67
O

These features help maintenance

personnel work more efficiently because
they receive asset information as problems
begin and not when the asset begins
performing farther outside its parameters
or fails, which is the ultimate inefficiency.

Integrated Data &

Simple, reliable
Mobile Interface
All these technologies generate data
from several different sources. For
efficient use, the data must be aggregated.
Cloud connection allows technicians
with handheld tools or sensors to take
efficient
measurements, and those measurements Vapor Recovery? LPG Transfer? Natural Gas Boosting?
are sent to the cloud. The answer is the FLSmidth® Ful-Vane™ rotary vane compressor!
These data, along with supervisory Uniquely designed for long service life, it has only three moving parts. Combined
with low operating speeds which minimizes wear and vibration, it is designed to
control and data acquisition and other
not only outlast other compressors, but save you money on
machine data, are then integrated with power and maintenance costs.
the EAM/CMMS to inform work orders for
Find out more at www.flsmidth.com/compressors
condition based maintenance activities.
This integration is carried out via
software that also allows the system to be Circle 141 on card or visit psfreeinfo.com.
operated on a mobile device. Maintenance
engineers can receive alarms within
seconds of an event.
A software system that integrates
SCADA and other machine/sensor
data with EAM/CMMS functionality
can seamlessly send workflows to be
completed to any connected device.
This gives the team the ability to
respond to fault notifications on the
move and then create, access or process
work orders related to the notification
in real time, paving the way for work
flow efficiency and improved asset
health for more efficient equipment
operation and longer system life.

To read more Maintenance Minders

articles, visit
pumpsandsystems.com/tags/
maintenance-minders

Frederic Baudart, CMRP, is a lead

application specialist for Fluke Accelix,
a suite of solutions from Fluke Corp. He
may be reached at frederic.baudart@
fluke.com. For more information, visit
accelix.com.
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p u m p s a n d s y s t e m s . c o m | M a rch 2018
68 SEALING SENSE

Compression Packing: A Look Beyond the

Standard Stuffing Box
How this application fits as a versatile solution

By Mark Freeman
FSA Member, EGC Engineered Solutions

S
tem packing is a familiar product.
The most common type is braided
compression packing. Braided
packing is used in a wide range of
applications. Depending on the service,
construction materials can be as diverse
as plants or animal derivatives, mineral
fibers or synthetic plastics and even
metal. The process of cutting rings from
rope packing, inserting them into a
stuffing box and torquing them to the
right density is common, but it is not
always the best choice.
Another widely used manufacturing
method is die-molding. It is the process
of wrapping a material around a mandrel,
placing it in a die and preforming it
to make a seal. Using these and other
manufacturing technologies, packing is
found to work in applications as different
as aerospace, heavy trucking and power
generation. A review of some unusual
applications demonstrates the versatility
of compression packing
as a sealing solution.
can leak into the bilge. Ancient sailors, Synthetic aramid fibers are abrasion-
using the top technology of the day, resistant and can handle higher
would take pieces of clothing, sail cloth temperatures and shaft speeds. PTFE
and rope, cover it with animal fat or wax has excellent lubricity and chemical
and stuff it into the gap around the shaft. resistance. Graphite coupled with mica
Eventually, a box was secured around or an aramid fiber can stave off the heat
the shaft and a gland, which could be generated by a rotating shaft and provide
tightened to compress the packing long life in challenging applications.
material, was created to improve sealing
and longevity.
The terms compression packing,
stuffing box and gland come from these
early sailors.
Compression Packing
Over time, many improvements in
packing construction and materials
were made. Packing today can be made
of fl ax, Kevlar, polytetrafluoroethylene
(PTFE), graphite or metal. It typically
has a square cross-section and is sold in
precut rings or in large coils, as shown in
Image 1.
Image 2. Die formed ring

The Origin
of Packing
Compression packing is
an ancient technology
dating back more than
5,000 years.
Boats and ships used
a rudder as a steering
mechanism. The rudder
shaft penetrates the
hull of the vessel below
the water line, so water
Image 1. Braided compression packing
(Images courtesy of the author)
Die-Formed Packing
Die-formed compression packings are
excellent in terms of sealing performance
and reliability and offer a wide range
of long-term, low-emission and low
maintenance products. See Image 2.
Not only are die formed rings easier
and quicker to install, but the pre-
compression increases the density
of each ring and reduces the gland
loads necessary to seat and compress

March 2 0 1 8 | Pumps & S y stem s


multiple rings in the stuffing box. The
result is lower friction on the shaft
or the spindle, with improved sealing
performance and a longer life.
Factor in STAMPS
As mentioned in an article previously
published by the Fluid Sealing
Association, (Sealing Sense, Pumps &
Systems, March 2005), there are several
key factors to consider when choosing
the right packing. They include:
• size or stuffing box bore
• temperature inside the stuffing box
application: whether it’s a pump,
valve, mixer, refiner, process,
characteristics such as pH level and
chemical compatibility
• motion: rotary, helical or reciprocal
• pressure inside the stuffing box
• surface speed expressed in feet per
minute or meters per second
Keeping this in mind, here are
some applications to consider when
you are going way beyond the typical
stuffing box.
Graphite and wire mesh for exhaust
systems. Die molded configurations of
flexible graphite, mica or vermiculite
densifies well when loaded in these
flange couplings to seal truck and auto
emissions before being cleaned by the
after-treatment and catalytic scrubbing
systems. Due to the high vibration in
these applications, wire mesh is used in
combination with the sealing material
to provide a skeleton, giving the sealing
material structure to add durability.
Ancient sailors would take pieces of clothing, sail
cloth and rope, cover it with animal fat or wax and
stuff it into the gap around the shaft. ... The terms
compression packing, stuffing box and gland come
from these early sailors.
69
Image 3. Die formed wire mesh
reinforced
Metal caps for pressure seals. In the
typical stem packing in a valve stuffing
box, the high axial to radial load
transition of a die-molded configuration
from the gland load creates the seal
around the stem. Bonnet pressure seals
were originally designed to be made
of solid metal and relied on process
pressure to effectuate a seal. The all-
metal seal used the angle of the bonnet
to amplify the unit load on the toe
creating a single point metal to
metal seal.
More recently, engineers found a
way to use the high axial to radial load
transfer of die molded flexible graphite
to create a full cavity seal. However,
they had to find a way to keep the
graphite from extruding under high unit
loads. The most common way was to
place a thin cap on the top and bottom
of the seal. As opposed to a full metal
ring sealing only at the toe, and having
Circle 143 on card or visit psfreeinfo.com.
a potential to damage the valve, the
p u m p s a n d s y s t e m s . c o m | M a rch 2018
70 SEALING SENSE
Image 4. Metal caps for pressure seals
packing-style die molded graphitic seal
fully compresses and densifies to fi ll and
seal throughout the entire bonnet cavity.
See Image 4.
Most of these pressure bonnet
valve configurations are found in
power generation facilities, and in
today’s environment, these plants are
on-demand requiring their units to cycle
in pressure and temperature frequently.
The unique capability of the die molded
flexible graphite to remain resilient at
ambient and high temperatures serves
this application well without causing
undue wear to the valve itself. These
valves are expected to be in service for
more than 50 years.
Valve balance seal. Balance seals are
very similar in nature to stem packing
in a rising stem valve. See Image 5.
They provide both an inside and outside
diameter seal for a linear motion device
and use axial load to compress the seal.
It is typical to see a wire reinforced ring
on the top and bottom to provide anti-
extrusion and wiping just like a valve
packing stuffing box. However, a balance
seal is designed into a closed cavity
configuration, which does not allow for
March 2 0 1 8 | Pumps & S y stem s
adjustments to be made while in service.
In some cases, the design requires that
the packing leaks to some extent
Dry bulk handling systems. Dry
bulk piping systems use braided
configurations of flexible graphite or
glass fibers as well as some polymers
to create a seal between the pipe
connections. Unlike a high-pressure
liquid or gas piping systems that use
Image 5. Integrated stem wiping
system
fl anges for fl at gaskets to connect the
joints, these systems use the axial to
radial load transfer that is inherent to
braided packing to seal the joint as well
as create a solid connection.
Die cut and coined parts. These highly
engineered parts are typically more
expensive than a standard die formed
or braided packing, but they have
significant advantages. This type of
inside and outside diameter sealing
device is pre-compressed to a high
density (see Image 6.)
It does not exert the same axial to
radial load transfer experienced with
other designs. The low axial to radial
load transfer reduces the amount of
friction caused by the packing set as well
as the amount of compression required
to create a seal. These types of sealing
devices are typically used in small
instrumentation devices.
Clamped joints. Strap and V-Band style
clamped joints can also benefit from the
use of die molded packing style seals.
The seal used in these configurations
also typically provides structure for
the joint as well. It keeps the piping
 71

Making fluid energy work for you.

FEDCO offers a
range of centrifugal
pumps and energy
recovery turbines for
clean fluid applications.
Since 1997 we have provided
custom desalination pumping
solutions around the world.

Image 6. Die cut and coined graphite Headquarters & Manufacturing

ring +734.241.3935 • sales@fedco-usa.com
Fluid Equipment Development Company, LLC
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from separating or rotating during high
vibration operation and thermal cycling. Singapore Office Dubai Office
These packings, in some cases, can be +65.9784.3813 +971.04.242.3856 www.fedco-usa.com
made in a composite construction of both Circle 140 on card or visit psfreeinfo.com.
molded sealing material mated with metal
components. The metal components can
then serve as a portion of the clamped
joint to achieve weight, cost savings and
ease of assembly.

Exhaust manifold packing. Some sealed

joints move with much smaller travel
than typical valve stem packing, but with
much higher frequency, vibration and
temperature. Exhaust manifold slip joints
sometimes use molded packing made from
high temperature materials like flexible
NEVER MISS A GAME–WINNING TOUCHDOWN AGAIN.
graphite and ceramics to keep soot, fuel
and exhaust from escaping. This is a very The 106 / S106 offers built-in redundancy for
challenging configuration for packing due times when you need backup capability.
to the fact that slip joints have a great More than just a pressure reducing valve, it
deal of clearance to allow for thermal can be used as a...
expansion and experience extreme
temperatures approaching 1,900 degrees • Level control valve
Fahrenheit (F) while operating in a high • Solenoid control valve
vibration environment. • Flow valve

Aerospace packing. Many do not know

that high temperature molded packing VISIT US TODAY!
materials such as flexible graphite also SINGERVALVE.COM
constitute an excellent sealing material
in cryogenic conditions. For example,
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p u m p s a n d s y s t e m s . c o m | M a rch 2018
72 SEALING SENSE

QUICK QUOTE
GUARANTEE
®
TITAN FLOW CONTROL, INC
Many do not know
SPECTACLE FLANGES that high temperature
OPEN/CLOSED BLINDS molded packing
RESTRICTION PLATES
materials such as
AND SO MUCH MORE!
flexible graphite also
constitute an excellent
sealing material in
B R I C AT I O
FA N
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cryogenic conditions.
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Custom Fabrication seals for the interconnects of fuel lines for

For Custom Solutions. the engines used to propel rocket launch
vehicles are sometimes made using die
910.735.0000 molded flexible graphite. These packing
www.titanfci.com titan@titanfci.com style components are required to survive
at -423 F and seal products like liquid
Circle 137 on card or visit psfreeinfo.com. hydrogen or oxygen. These are indeed
unique applications.

PINNACLE-FLO Next Month: Pipe strain impact

QUALITY•VALUE•ENGINEERING on gaskets

INDUSTRIES: We invite your suggestions

• Chemical Process for article topics as well
• Refinery as questions on sealing
• Oil & Gas Municipal issues so we can better
• Food Process Markets respond to the needs of the
• Water/Wastewater industry. Please direct your suggestions and questions to
PRODUCTS: sealingsensequestions@fluidsealing.com.
• ANSI Process
• API 610
• Centrifugal
Solids-handling Mark Freeman has been in business-
Self-prime Introducing Pinnacle-Flo, Inc. to-business communication for most
• Centrifugal MUD Fully Synthetic Oil
• Air Operated Double Pinnacle-Flo, Inc. and Royal Purple have of his life. As the marketing director for
Diaphragm Pumps teamed together to create a fully synthetic EGC, he is responsible for the strategy,
oil called MicroSyn 88. This is a
Clean, Dry, Long Life, High Film Strength, design, production and coordination of
Energy Efficient, Synthetic Lubricant that all marcom components. In addition
Significantly Increases Bearing Life and
Equipment Reliability. to having degrees from University of
MicroSyn 88 is shipped with every Missouri and John Carroll
one of our ANSI 8896 pumps as well as
our line of Self-Prime centrifugal pumps. University, he was the CEO
Contact Pinnacle-Flo, Inc. for the nearest of a 40-person advertising
stocking distributor.
Our on-sight engineers and professionally trained and public relations
sales staff support our network of distributors. agency called Mark
Freeman Advertising.
Pinnacle-Flo.com • Houston, Texas • 832-303-1245 • sales@Pinnacle-Flo.com
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March 2 0 1 8 | Pumps & S y stem s


Finding System Inefficiencies &
Positive Displacement Pump Basics
By Hydraulic Institute
How can I determine if my
pumping system is a good
candidate for improved energy
efficiency?
Below is a list of common
indicators that may signify a pumping
system contains inefficiencies:
• highly throttled flow control valves
• bypass line (recirculation) flow
regulation
• batch type processes in which one or
more pumps operate continuously
• frequent on/off cycling of a pump in a
continuous process
• presence of cavitation noise
• a parallel pump system with the same
number of pumps always operating
• a pump system that has undergone
a change in function without
modification
• a pump system with no means of
measuring flow, pressure or power
• a pump system with frequent failures
and high maintenance costs
The first step in system optimization
is performing an assessment and
documenting the indicators in the list.
Since a pumping system will operate at
Figure 3.1.4.2. Flexible tube
pump (peristaltic) (Images Figure 3.1.5b. Three-lobe
courtesy of HI) pump
the intersection of the pump curve and
system curve, the next step is to evaluate
the pumping system to determine the
baseline system requirements or system
curve. This is what the system requires
to meet its purpose, not what the current
state of the system is.
Next, system operating data should
be acquired with permanently installed
process transmitters or portable
instruments, which measure system
flow rates, system pressures and power
consumption. The data collection should
be done in a manner that allows pump
flow and head to be evaluated against
the system’s performance curve, and it
should be collected over an appropriate
amount of time to represent the normal
operating condition. For example,
systems with varying or seasonal loads
may require long-term data logging
equipment. After sufficient data is
collected, it should be compared to the
measured rates of flow/head and the
required rates of flow/head. This may
reveal an imbalance between measured
and required conditions.
To learn more about assessing
pumping systems and a new certification
program for Pump System Assessment
Figure 3.1.7.
Circumferential piston
pump
HI PUMP FAQS 73
Professionals (PSAP), refer to the PSAP
Body of Knowledge Guidebook and the
PSAP Certification Study Guide at pumps.
org/psap.
What are some common
positive displacement pumps
uses in the wastewater
industry?
Positive displacement pumps
provide a certain volume of liquid with
every revolution of the shaft that is
relatively independent of the differential
pressure, which makes them different
from rotodynamic or centrifugal pumps.
Water/wastewater treatment is the
second largest positive displacement
pump market. There are many kinds of
positive displacement pumps used in the
wastewater industry, but images for four
types are provided.
Peristaltic pumps are the most
common type of flexible member positive
displacement pumps. There is no need to
worry about corrosion or contamination
of parts with these pumps because the
fluid is contained within the tubing. In
addition, the simple design makes them
low cost and easy to service. These pumps
can also pump high viscosity fluids with a
high percentage of solids well.
Lobe pumps use lobes on the rotating
elements within the pump casing to
direct the pumped fluid. Since the lobes
do not contact each other, lobe pumps
can move large solids and slurry-laden
media. Two-lobed pumps tend to handle
larger solids and high-viscosity fluids
better than three-lobed pumps at the
expense of increased pulsation. Also,
rotor surfaces in the pump cooperate to
provide continuous sealing.
p u m p s a n d s y s t e m s . c o m | M a rch 2018
74 HI PUMP FAQS

CAN YOUR PUMP HANDLE

THIS?
Figure 3.1.8.1. Single-screw pump
or just this? (progressing cavity)

Circumferential piston pumps are well

suited for a wide range of applications due
to their relatively low speeds, low inlet
pressure requirements and large cavities.
In this kind of pump, each rotor has one or
more wing lobe elements, called pistons.
The fluid is carried from inlet to outlet
in spaces between piston surfaces. These
Pump Protection pumps can handle high viscosity fluids and
with Muffin Monster Grinders have low shear at low speeds.
Progressing cavity pumps’ unique
LEARN MORE AT JWCE.COM
design makes them versatile and useful
for handling difficult to pump fluids,
Circle 142 on card or visit psfreeinfo.com. such as highly viscous or abrasive fluids.
Progressing cavity pumps are commonly
used to pump raw sewage and sludges. In
CENTRIFUGAL addition, progressing cavity pumps can
pump shear sensitive fluids and fluids with
PUMPS large particles.
Not pictured but also commonly used

Your Best Value in Self Priming & for disinfectant are controlled-volume
metering pumps. These deliver flow
ANSI Centrifugal Pumps streams at adjustable, yet controlled,
rates with a high degree of accuracy.
These pumps are most commonly used
for the injection of chemical additives,
proportional blending of multiple
components, or metered transfer of
liquid additives.
For more information regarding pumps
used in the wastewater industry, refer
Model SN to the “Positive Displacement Pump
Certificate” training modules by at
Model 2196 ANSI pumps.org.
Located in Green Bay, WI
HI Pump FAQs® is produced by the Hydraulic
Celebrating over 33 years Institute as a service to pump users, contractors,
distributors, reps and OEMs. For more
Call or Email: information, visit pumps.org.
920-869-4800 TM

PUMP, Inc
sales@summitpump.com
www.SUMMITPUMP.com
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March 2 0 1 8 | Pumps & S y stem s


New & Notable Technology
Products selected by the Pumps & Systems editors
2 4 CORIOLIS MASS FLOW METER
1 FSIP design has been re-engineered to provide
1 STUFFING BOX SEALING
The SEALRYT PackRyt Diverter is a unique
stuffing box sealing arrangement that
incorporates an internal flush relocation
system within the composite bearing. This
configuration allows for flush relocation
to optimal position without stuffing box
modification. By moving the flush location, you
can drastically reduce flush usage. Field studies
and simulations have resulted in an 85 percent
reduction in flush. The bearing is customizable
for optimal performance in any application.
Circle 201 on card or visit psfreeinfo.com.
To have a product considered for this section, please send the information to Savanna Gray, sgray@cahabamedia.com.
2 PROGRESSIVE CAVITY PUMP
NETZSCH PUMPEN & SYSTEME GMBH has
added to its line of FSIP (full service-in-place)
NEMO progressive cavity pumps. Ideal for wear-
intensive applications, the maintenance-friendly
full access to all the pumps’ rotating parts.
NEMO FSIP is now available in six sizes (NM045
to NM105) for flow rates up to 180 m3 per
hour. NEMO FSIP models are now offered with
differential pressures up to 6 bar (1-stage) up to
12 bar (2-stage), identical to the performance
parameters of the standard series.
Circle 202 on card or visit psfreeinfo.com.
3 SOFTWARE
TRENDMINER announced that it has released
a new software version: TrendMiner 2017 R2.
This release focuses on leveraging global
connected data sources to unlock data insights
across the extended enterprise for optimizing
overall plant performance and profitability.
The latest TrendMiner release delivers key
enhancements to support companies with
globally dispersed sites and teams. TrendMiner
2017 R2 includes a recommendation engine to
help subject matter experts solve challenging
cases. This recommendation engine can
proactively suggest tags that may be relevant
to the analysis, including influence factors in
upstream process sections with potentially
significant time delays.
Circle 203 on card or visit psfreeinfo.com.
PRODUCTS 75
KROHNE INC. announces the new OPTIMASS
2000 S400 16-inch Coriolis mass flowmeter,
which features the highest flow capacity of any
Coriolis meter on the market. The large diameter
mass flow meter is ideal for bulk measurement
of petroleum and oil, as well as syrup, molasses
and raw chemicals. The meter has been approved
for custody transfer of liquids and gases. With its
unique four straight tube design, the OPTIMASS
2000 S400 features the smallest installation
footprint in its class and offers significant energy
savings with a lower pressure drop.
Circle 204 on card or visit psfreeinfo.com.
5 TABLET PC
ENDRESS+HAUSER introduced the Field Xpert
SMT70, a rugged tablet PC for commissioning and
maintenance staff to manage field instruments
and document the work progress. The Field
Xpert SMT70 supports HART, PROFIBUS DP/
PA, FOUNDATION Fieldbus, Modbus, CDI and
Endress+Hauser service interfaces. It can connect
to field instrumentation devices directly via a USB
or Bluetooth wireless modem, or via a gateway,
remote I/O or multiplexer to a bus system.
Circle 205 on card or visit psfreeinfo.com.
6 PROXIMITY SENSOR
AUTOMATIONDIRECT’S new V3 series AC
powered inductive proximity sensors are available
in 8, 12, 18 and 30mm sizes. Extended sensing
distances for these new sensors range from 2 mm
shielded and 4 mm unshielded for 8 mm sensors
to 12 mm shielded and 18 mm unshielded for 30
mm sensors. These sensors operate on 20-250
VAC/VDC input voltage with N.O. and N.C. output
options available.
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p u mp s a n d s y s te m s . com | M a rch 2018
76 PRODUCTS

9
8

9 AEROBIC DIGESTER SOLUTION

7 AUTOMATION SOLUTION
MAAG’S enhanced extrusion controller maax
400S features a 12 inch monitor and
can control up to four variable speed drives.
It can be upgraded up to a maximum of 32
heating/cooling zones (in the basic software
configuration). The maax 400S retains the
intuitive user control, screen page layout and
color concept of the existing controllers. This
control solution enables customer-specific
requirements, such as page layout, additional
pages or special component control, to be met
within certain bounds.
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8 SWING CHECK VALVES
To meet the higher pressure requirements of
today’s water infrastructure systems, all 2- to 12-
inch MUELLER UL/FM swing check valves are now
rated at 350 psig cold working pressure (CWP). In
addition, the product line has been expanded to
include 2-, 14-, and 16-inch sizes (with the largest
two sizes still rated at 250 psig CWP). Standard
features of Mueller UL-listed, FM-approved check
valve product line now include: all ductile iron
construction, bronze to BUNA seating, lifting rings
and PN16 drilling.
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XYLEM launched a new aerobic digester solution
under its Sanitaire brand that decreases energy
consumption by up to 90 percent, promoting
more sustainable wastewater treatment
operation. Sanitaire Vorelodos aerobic digester
combines equipment, controls and services
to future-proof wastewater treatment plants
by ensuring they meet current and future EPA
effluent and biosolids regulations. The digester
is suitable for newly constructed conventional
activated sludge plants or upgrades to existing
plants over 0.5 million gallons per day (MGD),
as well as oxidation ditch upgrades and aerobic
digester aeration retrofits.
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March 2 0 1 8 | Pum ps & S y st e m s

 PUMP USERS MARKETPLACE 77

Ad v e r t i s e rs
Advertiser Name RS# Page Advertiser Name RS# Page Advertiser Name RS# Page

AE Pumps . . . . . . . . . . . . . . . . . . . . . . . . .163 78 HCP Pumps America Inc . . . . . . . . . . . .124 55 Schenck Trebel Corp . . . . . . . . . . . . . . . 133 51
AutomationDirect .com . . . . . . . . . . . . .102 BC Helwig Carbon Products . . . . . . . . . . . .148 63 Sensaphone . . . . . . . . . . . . . . . . . . . . . . . 134 25
Badger Alloys . . . . . . . . . . . . . . . . . . . . . 121 52 Hydraulic Institute . . . . . . . . . . . . . . . . 125 56 Singer Valve . . . . . . . . . . . . . . . . . . . . . . . .144 71
Baldor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 13 Hydro, Inc . . . . . . . . . . . . . . . . . . . . . . . . . .101 IFC Specialty Pump &
Bartlett Bearing Company . . . . . . . . . 122 27 InfoSight Corporation . . . . . . . . . . . . . .170 79 Equipment Co . Inc . . . . . . . . . . . . . . . 159 78
BJM Pumps . . . . . . . . . . . . . . . . . . . . . . . 139 67 JDA Global . . . . . . . . . . . . . . . . . . . . . . . 126 30 St . Marys Foundry . . . . . . . . . . . . . . . . . 150 76
Blue-White Industries Ltd . . . . . . . . . . .118 9 JDA Global . . . . . . . . . . . . . . . . . . . . . . . 127 31 Stoffel Polygon Systems Inc . . . . . . . . 135 54
Conhagen, Inc . . . . . . . . . . . . . . . . . . . . . 123 36 JWC Environmental . . . . . . . . . . . . . . . .142 74 Summit Pump . . . . . . . . . . . . . . . . . . . . .145 74
Crane Pumps & Systems . . . . . . . . . . . 104 21 KSB, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 3 Summit Pump . . . . . . . . . . . . . . . . . . . . .146 65
Dan Bolen & Associates, LLC . . . . . . . 153 79 Load Controls, Inc . . . . . . . . . . . . . . . . . 128 44 Titan Flow Control, LLC . . . . . . . . . . . . 137 72
Titan Pumps . . . . . . . . . . . . . . . . . . . . . . .160 78
Equipump . . . . . . . . . . . . . . . . . . . . . . . . 154 78 Load Controls, Inc . . . . . . . . . . . . . . . . . 155 77
Unlaub . . . . . . . . . . . . . . . . . . . . . . . . . . . .152 79
FEDCO . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 71 Lobe Pro Rotary Pumps . . . . . . . . . . . . 156 77
Vaughan Company . . . . . . . . . . . . . . . . .114 5
Flowrox . . . . . . . . . . . . . . . . . . . . . . . . . . .119 11 M & C Pump Americas . . . . . . . . . . . . . .149 63
Vertiflo Pump Company . . . . . . . . . . . .161 79
Flowrox . . . . . . . . . . . . . . . . . . . . . . . . . . .105 IBC Magnatex Pumps, Inc . . . . . . . . . . . . . . .157 77
Vesco Plastics Sales . . . . . . . . . . . . . . . . .162 79
Flowserve Corporation . . . . . . . . . . . . . 106 19 MasterBond Inc . . . . . . . . . . . . . . . . . . . 158 79
Watson-Marlow Pumps . . . . . . . . . . . . 138 45
Flowserve Corporation . . . . . . . . . . . . . .107 7 Metrix Instrument Company . . . . . . . .143 69 WILO USA LLC . . . . . . . . . . . . . . . . . . . . 115 39
FLSmidth . . . . . . . . . . . . . . . . . . . . . . . . . .141 67 Nidec Corporation . . . . . . . . . . . . . . . . . 130 57 Zoeller Pump Company . . . . . . . . . . . . . .117 41
Fluke Corporation . . . . . . . . . . . . . . . . . 108 33 Peak Mechanical & Components, Inc ./
Fluke Corporation . . . . . . . . . . . . . . . . . .109 15 APEX Heavy Duty . . . . . . . . . . . . . . . 131 50 The Index of Advertisers is furnished as a
Franklin Electric . . . . . . . . . . . . . . . . . . 120 17 Pinnacle-Flo . . . . . . . . . . . . . . . . . . . . . . .147 72 courtesy, and no responsibility is assumed for
Garlock Sealing Technologies . . . . . . . .110 35 PumpWorks Industrial . . . . . . . . . . . . . 113 23 incorrect information.

Go with the PRoS!! LoBePRo RotaRy PumPS

Sub ANSI magnetic drive pumps Why LobePro Rotary Lobe Pumps?
• Low maintenance - • Excellent for abrasives,
IN STOCK, READY TO QUICK SHIP. “in place” wear part solids & viscous fluids
replacement • Forward and reverse
• Run dry ability pumping operation
Pump Capacities up to 2,656 GPM (604 m³/hr) with
discharge pressure ratings to 175 psi (12 bar)
To learn more or get a custom quote, email PumpSales@lobepro.com
912-466-0304 www.LOBEPRO.com Made in USA
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MONITOR PUMP PERFORMANCE

• Flow Rate univeRsal PoweR Cell
• One Size Adjusts for
• PumP Condition All Motors, From Small
up to 150HP
• dRy Running • Works on Variable Frequency
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Call now FoR youR FRee 30-day tRail
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p u mp s a n d s y s te m s . com | M a rch 2018

78 PUMP USERS MARKETPLACE

FREE PRODUCT INFORMATION

Visit psfreeinfo.com to request more information from these advertisers.

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MOBILE
CONNECTIONS
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ON THE GO
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• Custom redesigned and engineered pumps
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• Obsolete drop-in replacements
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M a rch 20 1 8 | Pumps & S y st e m s

 79

Solve
dry start
problems with
Vesconite Hilube
bushings
 Increase MTBR
 No swell
 Low friction = reduced
electricity costs
 Quick supply.
No quantity too small
Tollfree 1-866-635-7596
vesconite@vesconite.com
www.vesconite.com
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U-DISC 6-bolt UNITIZED EXECUTIVE SEARCH/RECRUITING

SPACER DISC COUPLING
The U-DISC 6-bolt unitized spacer
disc coupling is a power dense,
maintenance-free shaft coupling
that has guaranteed same day
shipping. If U-DISC engineers design “Serving the Pump &
it, and you install it properly—the
U-DISC coupling will have infinite Rotating Equipment, Valve,
life. The U-DISC coupling complies and Industrial Equipment
with API-610 standards and is
stocked in Tulsa Industry since 1969”
EXCELLENT CHEMICAL RESISTANCE
and Houston. Domestic & International

Specializing in placing:
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• General Management • Engineering
• Sales & Marketing • Manufacturing
WITHSTANDS THERMAL CYCLING DAN BOLEN • JASON SWANSON
CHRIS OSBORN • JULIAN MUELLER

9741 North 90th Place, Suite 200

U-DISC Scottsdale, Arizona 85258-5065
800-299-5104 154 Hobart St., Hackensack, NJ 07601 USA (480) 767-9000 • Fax (480) 767-0100
engineering@u-disc.com +1.201.343.8983 ∙ main@masterbond.com Email: dan@danbolenassoc.com
u-disc.com www.masterbond.com www.danbolenassoc.com
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p u mp s a n d s y s te m s . com | M a rch 2018

80 PUMP MARKET ANALYSIS
Wall Street Pump & Valve Industry Watch
By Jordan, Knauff & Company
T
he Jordan, Knauff &
Company (JKC) Valve Stock
Index was up 14.9 percent
over the last 12 months, while the
broader S&P 500 Index was up 23.8
percent. The JKC Pump Stock Index
increased 9.2 percent for the same
time period.1
The Institute for Supply
Management’s Purchasing
Managers’ Index (PMI) fell
slightly in January, dropping to
59.1 percent from 59.3 percent in
December. The Production Index
remained above 60 percent for the
eighth consecutive month at 64.5
percent. New Export Orders rose to
59.8 percent, the highest reading in
almost seven years. The Prices Index
rose 4.4 percent over the month,
rising to 72.7 percent, a reading not
seen since 2011.
The U.S. created 200,000 new jobs
in January, while unemployment
remained at a 17-year low of 4.1
percent. Construction companies
added 36,000 jobs, restaurants
hired 31,000 new workers, health
care firms increased jobs by 21,000,
while manufacturing increased
by 15,000 workers. Over the last
three months, the U.S. has gained
an average of 192,000 new jobs.
Average hourly wages increased 0.3
percent, pushing the yearly increase
Figure 2. U.S. energy consumption and rig counts
Source: U.S. Energy Information Administration and Baker Hughes Inc.
March 2 0 1 8 | Pum ps & S y st e m s
to 2.9 percent.
The Census Bureau
reported that U.S. total
private residential
construction spending
rose 0.5 percent in
December to a seasonally
adjusted annual rate of Figure 1. Stock Indices from February 1, 2017 to January 31, 2018
$526.1 billion, the highest
level since March 2007. Local currency converted to USD using historical spot rates. The JKC Pump and Valve
Stock Indices include a select list of publicly traded companies involved in the pump and
Total private residential valve industries, weighted by market capitalization. Source: Capital IQ and JKC research.
construction spending
rose 6.2 percent last Dakota at 1.18 million barrels per
year versus 12.5 percent in 2016. day. The U.S. Energy Information Reference
Reaching a $64 billion annual Administration estimates that 1. The S&P Return
pace in December, the increase about half of the November 2017 figures are provided
by Capital IQ.
in multifamily construction crude oil production came from
spending rebounded strongly at tight formations which reached
2.6 percent after a drop of 0.5 5.09 million barrels per day. This Jordan, Knauff
percent in November. Single-family passes the previous high of 4.7 & Company is an
investment bank
construction spending inched up million barrels per day from these based in Chicago that
0.4 percent, after surging 2 percent formations in March 2015. provides merger and
in November. On Wall Street for the month of acquisition advisory
services to the
For the first time since 1970, January the Dow Jones Industrial pump, valve and
monthly U.S. crude oil production Average rose 5.8 percent, the S&P filtration industries.
surpassed 10 million barrels per 500 Index increased 5.6 percent Please visit
jordanknauff.com for
day, reaching 10.038 million barrels and the NASDAQ Composite grew further information.
per day last November. It is also 7.4 percent. The markets’ strong Jordan, Knauff &
the second highest U.S. monthly performance was the result of an Company is a member
of FINRA.
oil production value reported, just upbeat fourth quarter earnings
below the 10.044 million barrels per season, the passage of the Tax
day in November 1970. November Cuts and Jobs Act of 2017 that cut
2017 production reached a record corporate tax rates, and the Federal These materials were
prepared for informational
high in Texas at 3.89 million Reserve Bank’s encouraging outlook purposes from sources that
are believed to be reliable
barrels per day, followed by North for the economy. but which could change
without notice. Jordan,
Knauff & Company and
Pumps & Systems shall not
in any way be liable for
claims relating to these
materials and makes no
warranties, express or
implied, or representations
as to their accuracy or com-
pleteness or for errors or
omissions contained herein.
This information is not
intended to be construed
as tax, legal or investment
advice. These materials do
not constitute an offer to
buy or sell any financial
security or participate in
Figure 3. U.S. PMI and manufacturing shipments any investment offering or
deployment of capital.
Source: Institute for Supply Management Manufacturing
Report on Business and U.S. Census Bureau
 Safety & Benefits of
PACKAGED PUMP
SYSTEMS APRIL 12, 2018
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* See our Web site for details and restrictions. © Copyright 2017 AutomationDirect, Cumming, GA USA. All rights reserved. 1-800-633-0405 the #1 value in automation

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